Automated Face Conveyor Chain Tension Load Sensor
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Solution Overview
Problem
Conventional armored face conveyors lack effective mechanisms for detecting and adjusting scraper chain tension, leading to potential chain breakage and equipment damage due to varying loads and repositioning, with operators relying on manual adjustments that are slow and difficult, especially in environments where direct steering is unavailable.
Innovation Solution
The implementation of sliding frames at both ends of the conveyor with integrated tension sensors and hydraulic systems allows for independent adjustment of conveyor ends to maintain optimal chain tension and detect broken chains, preventing further damage and enabling quick alignment with coal blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment of conveyor position is used to maintain chain tension, then chain tension can be maintained, but the adjustment process is slow and difficult
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect chain tension and actuators to adjust the conveyor position automatically, eliminating the need for operators to manually gauge and adjust tension while significantly increasing adjustment speed
Solution Approach 2:
The patent implements a feedback control system where sensors continuously monitor chain tension and feed this information to a control system that automatically adjusts the conveyor position to maintain optimal tension, creating a closed-loop system that responds dynamically to tension changes
2Reliability
If operators manually detect broken chain by visual inspection, then chain breakage can be detected, but the opportunity for detection is reduced due to safety requirements and mineral coverage
Solution Approach 1:
The patent replaces manual visual inspection with automated sensors that detect chain breakage through tension changes in the chain, eliminating the need for operators to visually inspect the chain while safely maintaining detection capability despite mineral coverage and safety restrictions
Solution Approach 2:
The patent uses tension sensors as intermediaries to indirectly detect chain breakage by measuring changes in chain tension, rather than requiring direct visual contact with the chain itself, thus overcoming the limitations of manual detection methods
3Reliability
If extendable return end frame is used to take-up slack chain, then chain tension can be maintained, but the complexity of the conveying system increases
Solution Approach 1:
The patent implements a self-regulating system where the extendable return end frame automatically adjusts its position based on real-time chain tension measurements, eliminating the need for complex manual control mechanisms while maintaining chain tension through automated feedback control
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
This solution ensures reliable chain tension monitoring and automatic adjustment, reducing the risk of chain breakage and equipment damage while allowing for precise alignment with coal blocks, thereby minimizing downtime and improving operational efficiency.
Implementation Method 1
a load cell (128) located between the wear plate (132) and the wear strip support (136)... the load cell (128) responds to the force applied to the wear plate (132) by the conveyor (16)
Implementation Method 2
hydraulic systems allows for independent adjustment of conveyor ends to maintain optimal chain tension
Data Source
AI summary
A device is provided for detecting and adjusting the tension of the scraper chain. The device identifies broken chain as it leaves the return sprocket and enters the top race of the conveyor. When detected, the chain can be stopped automatically by the armored face conveyor control system, to avoid the potential for further damage, and warn the operators that repair of the chain is required.The device also provides a conveyor with sliding frames at both ends to allow the conveyor ends to be independently adjusted to each end of the coal block, whilst maintaining good chain tension and control.