Optical Fiber Shearer Rocker Arm Angle Detection
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Solution Overview
Problem
Current methods for automatic drum height adjustment in shearer machinery lack precision, are prone to electromagnetic interference, and have explosion-proof and dust-related issues, which affect the reliability and longevity of the sensor systems.
Innovation Solution
A device using optical fiber sensing with a broadband light source, polarizer, gradient-rotation media plate, and data processing module, combined with a mechanical system including connecting rods and a slider, to measure the angle of the shearer rocker arm with high precision and resistance to electromagnetic interference, and inherent explosion-proof properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic field-based angle sensor is used, then the angle of the rocker arm can be detected, but the sensor is susceptible to electromagnetic interference and lacks explosion-proof capability
Solution Approach 1:
The patent replaces the magnetic field-based sensing system with an optical fiber-based sensing system. The optical fiber sensor detects angle changes through mechanical deformation of the fiber itself, eliminating susceptibility to electromagnetic interference while maintaining measurement capability. This substitution of the physical sensing mechanism directly addresses the electromagnetic interference problem.
Solution Approach 2:
The patent changes the detection parameter from magnetic field strength to optical signal characteristics (intensity, phase, or polarization changes). By measuring optical parameter variations caused by mechanical deformation of the optical fiber, the system achieves angle detection without relying on magnetic fields, thus avoiding electromagnetic interference issues.
2Measurement precision
If a circuit-based angle sensor is used, then the angle can be measured, but explosion-proof and suppression considerations complicate the system
Solution Approach 1:
The patent replaces the circuit-based sensing system with an optical fiber-based system that has no electrical components. The optical fiber sensor uses purely mechanical and optical principles, eliminating the need for complex explosion-proof electrical shielding and suppression circuits while maintaining angle measurement functionality.
Solution Approach 2:
The patent extracts and removes all electrical circuit components from the sensing system, retaining only the mechanical structure and optical fiber elements. This extraction of electrical components eliminates the complexity of explosion-proof and suppression requirements while preserving the core angle measurement function.
3Measurement precision
If a sensor with a rotation shaft and magnetic steel is used, then angle detection is achieved, but the sensor is vulnerable to dust ingress and bearing stress
Solution Approach 1:
The patent replaces the mechanical rotation shaft and magnetic steel system with an optical fiber bending-based sensing mechanism. The optical fiber detects angle changes through its deformation pattern, eliminating the need for rotating mechanical components that are susceptible to dust ingress and bearing stress, thereby improving reliability.
Solution Approach 2:
The patent removes the vulnerable mechanical components (rotation shaft, magnetic steel, bearing) from the sensor system and retains only the optical fiber and housing structure. This extraction of problematic components eliminates dust ingress pathways and bearing stress issues while maintaining angle detection capability.
4Measurement precision
If alignment precision between the rotation shaft and hinge pin is required, then accurate angle measurement is achieved, but mounting complexity and stress on bearings increase
Solution Approach 1:
The patent replaces the alignment-critical mechanical coupling system with an optical fiber-based system that is inherently insensitive to alignment precision. The optical fiber can be simply embedded in the housing without requiring precise alignment with the hinge pin, as it detects angle changes through its deformation rather than through geometric alignment, thereby simplifying manufacturing.
Solution Approach 2:
The patent separates the sensing function from the mechanical coupling function. The optical fiber sensor is embedded in the housing as an independent sensing element, decoupling it from the precise alignment requirements of the mechanical rotation system. This segmentation allows the sensor to be manufactured and installed independently without requiring precise alignment with the hinge pin.
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 solution provides a precise, robust, and explosion-proof method for detecting the angle of the shearer rocker arm, overcoming previous limitations by converting rocker arm movement into optical fiber displacement measurements, ensuring high accuracy and reliability in adverse mining conditions.
Implementation Method 1
A device for detecting an angle of a shearer rocker arm based on optical fiber sensing is provided
Implementation Method 2
a gradient-rotation media plate (4)... due to an optical rotation effect, a plane of polarization of the linearly polarized light produces a rotation angle during passing through the gradient-rotation media plate
Data Source
AI summary
A device and method for detecting an angle of a shearer rocker arm based on optical fiber sensing. The device includes an optical system and a mechanical system. The optical system includes a broadband light source, a polarizer, collimating lenses, a gradient-rotation media plate, a polarization beam splitter, and a data processing module. The mechanical system includes a connecting base, connecting rods, a slider, a bracket, and a sensor housing. When the shearer operates, the rocker arm converts rotation angle information to linear displacement related to a gradient refractive index by using a connecting rod mechanism, and a position on the gradient-rotation media plate through which linearly polarized light produced by the optical system passes also changes. Due to an optical rotation effect, corresponding rotation angles of a plane of polarization that are formed after the light passing through the gradient-rotation media plate also vary.