Shearer Drum Vibration Monitoring via Laser Vibrometry
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Solution Overview
Problem
Current vibration monitoring methods for shearer drums in underground coal mines are indirect, prone to interference from strong electromagnetic fields, and lack sensitivity and precision, making it difficult to accurately monitor radial and axial vibrations in real-time without shutting down or disassembling the equipment.
Innovation Solution
A synchronous monitoring device using a laser, optical fiber couplers, photodetectors, and signal processing modules integrated into an intrinsically safe explosion-proof box on a shearer ranging arm, with a reflective coating on the drum for non-contact, direct measurement of phase and intensity changes to determine axial and radial vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an indirect monitoring method with electrical sensors is used, then the monitoring system can be implemented, but the monitoring sensitivity is low and the health state cannot be accurately reflected due to electromagnetic field interference
Solution Approach 1:
The patent replaces electrical sensors with optical sensors (laser vibrometer) to measure drum surface vibration. The laser beam reflects off the drum surface and detects radial and axial vibrations without electrical components, eliminating electromagnetic field interference while maintaining high measurement precision.
Solution Approach 2:
The patent introduces a reflective coating on the drum surface as an intermediary. The laser beam reflects off this coating to detect vibrations, allowing non-contact measurement while the coating enhances the reflection quality for more accurate detection of both radial and axial vibration components.
2Measurement precision
If direct contact monitoring is used, then high precision can be achieved, but the equipment must be shut down or disassembled for installation
Solution Approach 1:
The patent uses non-contact optical measurement (laser vibrometry) instead of physical contact sensors. The laser beam measures drum surface vibration without touching the rotating drum, eliminating the need to shut down or disassemble the equipment while achieving high measurement precision for both radial and axial vibrations.
Solution Approach 2:
The laser vibrometer system is designed to simultaneously measure both radial and axial vibration components of the drum through a single non-contact setup. This multi-functional capability allows comprehensive vibration monitoring without requiring multiple separate measurement systems or equipment shutdowns.
3Object-affected harmful factors
If optical sensors are used for non-contact monitoring, then electromagnetic interference is avoided, but the system complexity increases due to multiple optical components
Solution Approach 1:
The patent replaces complex electrical sensor systems with an optical measurement system. The laser vibrometer uses optical components (laser source, optical fiber, photodetector) to measure vibrations, providing immunity to electromagnetic field interference. The system complexity is managed by using standard optical components and a reflective coating on the drum.
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
Enables high-sensitivity, precise, and real-time monitoring of shearer drum vibrations, improving operational reliability and reducing economic losses by avoiding electromagnetic interference, and allowing continuous operation without shutdown or disassembly.
Implementation Method 1
an end face of a shearer drum perpendicular to a rotation axis is provided with a reflective coating perpendicular to parallel light emitted from the optical fiber collimator
Implementation Method 2
a first optical fiber coupler, an optical isolator, a second optical fiber coupler, a third optical fiber coupler
Implementation Method 3
a first photodetector, a second photodetector
Data Source
AI summary
A synchronous monitoring device and a method for radial and axial vibration of a shearer drum. The monitoring device includes a laser, a first optical fiber coupler, an optical isolator, a second optical fiber coupler, a third optical fiber coupler, an optical fiber collimator, a first photodetector, a second photodetector, a first signal processing module, and a second signal processing module which are disposed on a shearer ranging arm, as well as a reflective coating disposed on a shearer drum. By measuring a phase difference between original light and reflected light, axial vibration of the shearer drum is monitored, and by measuring an intensity difference between original light and reflected light, radial vibration of the shearer drum is monitored.