Scraper Conveyor Chain Tension Estimation via Embedded Strain Sensors
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Solution Overview
Problem
The chain of a scraper conveyor in coal mining faces frequent failures due to varying tension caused by external factors, leading to issues like chain breakage and uneven tension distribution, which existing methods fail to effectively address.
Innovation Solution
A method involving strain sensors embedded in scrapers to measure tension at weak coupling points, using interpolation and an adaptive Kalman filter to estimate and predict chain tension distribution, optimized by a data control center, with wireless data transmission for efficient data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain sensors are embedded in multiple scrapers to measure tension at multiple points, then measurement precision of chain tension distribution is improved, but device complexity increases
Solution Approach 1:
The chain tension measurement system is segmented into multiple independent measurement points along the chain path. Strain sensors are embedded in specific scrapers at strategically selected positions to measure tension at discrete points. This segmentation allows comprehensive tension distribution measurement while keeping each sensor unit simple and independent.
Solution Approach 2:
The scraper acts as an intermediary element between the chain and the strain sensor. The strain sensor is embedded in the scraper to measure the force transmitted from the chain through the scraper structure. This intermediary approach enables tension measurement without directly attaching sensors to the chain itself, simplifying the measurement system.
2Reliability
If real-time tension monitoring of the entire chain is implemented, then reliability of chain operation is improved, but device complexity and cost increase
Solution Approach 1:
Instead of instrumenting the entire chain with sensors at every point, the system uses partial measurement action by selecting key critical positions along the chain path for sensor placement. The strain sensors are embedded in specific scrapers at locations where tension characteristics are most representative or critical, providing sufficient information for reliability assessment without full-chain instrumentation.
Solution Approach 2:
The scraper structure itself serves the dual function of material handling and tension measurement. By embedding strain sensors in the scraper, the scraper becomes self-instrumented, eliminating the need for separate measurement devices attached to the chain. The scraper's existing structure is utilized for both its primary function and as a mounting platform for sensors.
3Productivity
If interpolation methods are used to estimate tension between measurement points, then productivity of tension estimation is improved, but measurement precision may be compromised
Solution Approach 1:
The system performs preliminary action by pre-establishing the coupling relationship model between tension at different chain points based on correlation analysis. This pre-established model captures the inherent relationships and patterns in chain tension distribution, enabling rapid interpolation estimation at measurement points while maintaining accuracy through the physically-based correlation model rather than simple mathematical interpolation.
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 method effectively addresses chain failure by accurately estimating and managing chain tension, reducing the likelihood of breakage and uneven tension issues, ensuring reliable operation of the scraper conveyor.
Implementation Method 1
embedding strain sensors in a plurality of scrapers of a scraper conveyor, obtaining the tension of corresponding weak coupling point by measuring the force borne by the contact point between the scraper and the chain
Data Source
AI summary
Disclosed is a method for estimating tension of a chain of a scraper conveyor, belonging to a method for estimating chain tension. The method comprises the following steps: embedding strain sensors in a plurality of scrapers of a scraper conveyor to measure the tension of weak coupling points between the scrapers and chains, converting acquired sensor signals into data signals through an A/D conversion unit, transmitting the data signals to a data control center using a wireless transmission module, further processing the tension data information of the weak coupling points through the data control center, establishing a chain tension distribution model, and determining an the estimated tension of the chain of the scraper conveyor. The method provided by the present invention is simple, efficient and practical, and the estimation of tension of the whole continuous moving chain is completed by the tension measurement at limited positions of the chain. The chain of the scraper conveyor is meshed with a sprocket and continuously moves in a middle trough and its tension also changes in real time along with the load; the strain sensors are arranged on the scrapers to measure the tension of the weak coupling points between the scrapers and the chains, and the estimation of tension of the whole chain is completed by tension measurement at limited positions on the chain.