Double-End Chain Tensioning for Flight Conveyor Cylinder Reliability
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Solution Overview
Problem
Existing tail tensioning systems for cross side-dumping type flight conveyors in coal transportation suffer from structural deformation and manual adjustment inefficiencies, leading to frequent shutdowns and reduced service life due to hydraulic cylinder wear and failure.
Innovation Solution
A double-end chain tension force control system with coordinated head and tail tensioning systems, utilizing hydraulic assemblies and intelligent control through deep learning and reinforcement learning to adjust tension forces automatically, ensuring normal operation even if one end fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a tail tensioning system is used to achieve dynamic compensation of chain extension, then the chain tension force can be adjusted, but the hydraulic cylinders expand and contract too long causing structural deformation and eventual failure
Solution Approach 1:
The single tail tensioning system is segmented into two independent tensioning systems: a head tensioning system and a tail tensioning system. Each system can independently adjust tension forces, allowing the total tension compensation to be achieved with half the stroke length for each hydraulic cylinder, thereby preventing structural deformation and improving reliability.
Solution Approach 2:
The problem is solved by adding a spatial dimension: instead of having the tail tensioning system handle all tension compensation alone, the head tensioning system is introduced at the other end of the conveyor. This dimensional distribution allows each end to contribute equally to tension control, reducing the required stroke length for each hydraulic cylinder.
2Ease of operation
If manual tensioning is performed when automatic control fails, then the chains can be tensioned, but the effect is not as good as automatic tensioning and shutdown maintenance is required
Solution Approach 1:
The control system is designed with local independence: each tensioning system (head and tail) has its own hydraulic assembly and control mechanisms. When one end fails, the other end can continue to maintain tension forces locally, allowing the conveyor to operate continuously without requiring shutdown maintenance, thus preserving productivity.
3Adaptability or versatility
If the tail tensioning system is used for dynamic compensation, then chain extension can be compensated, but the telescopic quantity is too large causing hydraulic cylinders to get stuck
Solution Approach 1:
The chain extension compensation function is segmented between the head and tail tensioning systems. Each system handles approximately half of the total extension compensation, reducing the individual stroke length requirement for each hydraulic cylinder from a problematic large value to a manageable smaller value, preventing the cylinders from getting stuck.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces structural deformation risks, improves responsiveness, and maintains efficient coal transportation by allowing the functioning of the other end when one end fails, thus extending the system's lifespan and reducing unscheduled shutdowns.
Implementation Method 1
hydraulic assemblies, driving the telescopic middle groove assembly to slide on the movable frame in the conveying direction of the flight conveyor
Implementation Method 2
the permanent magnet motors driving the reducers
Implementation Method 3
the driving sprockets being used for being connected to a flight conveyor chain
Implementation Method 4
a flow guiding plate and a flow guiding plate, fixed above the S coal falling plate, the flow guiding plate being arc-shaped and being vertically arranged at a front side of the coal guiding plate and used for changing a flow direction of coals
Data Source
AI summary
The present invention belongs to the technical field of coal transportation on fully mechanized mining faces, and particularly relates to a double-end chain tension force control system for a cross side-dumping type flight conveyor and a control method therefor. The double-end chain tension force control system includes a tail tensioning system, connected to a reversed loader at a tail of the flight conveyor; a head tensioning system, connected to a head of the flight conveyor, where the tail tensioning system and the head tensioning system together achieve double-end coordinated control of a chain transmission system on the flight conveyor to adjust a tension force; and a control system, collecting information about the tail tensioning system and the head tensioning system and controlling same. According to the present invention, a telescopic head mechanism for the cross side-dumping type flight conveyor is designed, and the double-end coordinated control of the chain transmission system can be achieved to rapidly adjust the tension force.