Note: Descriptions are shown in the official language in which they were submitted.
CA 02987475 2017-11-28
SCRAPER CONVEYER SPROCKET WHEEL TOOTH ABRASION
MONITORING DEVICE AND METHOD
BACKGROUND
Technical Field
The present invention relates to the technical field of the monitoring and
safety
guarantee of scraper conveyer equipment, and in particular to a scraper
conveyer sprocket
wheel tooth abrasion monitoring device and method.
Related Art
A scraper conveyer is main production and conveying equipment for underground
fully
mechanized coal faces of coal mines, and assumes the important tasks of
conveying coal,
providing pushing supporting points for hydraulic supports and providing
traveling tracks
for coal mining machines, and their reliability directly affects the safe and
efficient
production of modem coal mines.
A scraper chain is a mechanism, which can easily go wrong, of the scraper
conveyer,
and the failure accounts for about 40 percent of the total number of failures
of the scraper
conveyer. Once the scraper chain fails, the time needed by maintenance is
long, and as a
result, the production efficiency of large coal mines in our country is
severely restricted. It
is discovered in in-depth analysis that after sprocket wheel teeth are abraded
severely, the
skipping phenomenon of a chain of the scraper conveyer will take place when
the chain is
engaged with the sprocket wheel teeth, moreover, the risk of sprocket wheel
tooth breakage
exists, but there are no mature detection techniques for sprocket wheel tooth
abrasion loss
at home and abroad at present. Therefore it is necessary to monitor the
abrasion condition
of the sprocket wheel teeth in the running process of the scraper conveyer in
real time.
SUMMARY
Objective of the invention: Aiming at the safety monitoring problem existing
in the
process of using a scraper conveyer, the present invention provides a scraper
conveyer
sprocket wheel tooth abrasion monitoring device and method to implement the
real-time
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measurement of sprocket wheel tooth abrasion loss, providing technical support
for the
prevention of the chain skipping and sprocket wheel tooth chain breakage of
the scraper
conveyer caused by the severe abrasion of the sprocket wheel teeth.
In order to achieve the above, the present invention adopts the following
technical
solution: disclosed is a scraper conveyer sprocket wheel tooth abrasion
monitoring device,
which includes top reflective stickers, vertical photoelectric sensing
modules, side reflective
stickers, horizontal photoelectric sensing modules, and a data analysis
module;
the top reflective stickers are mounted on the top surfaces of sprocket wheel
teeth, each
vertical photoelectric sensing module includes a vertical light source and a
vertical
photoelectric sensing element, the vertical light sources are configured to
emit light toward the
top reflective stickers, and the vertical photoelectric sensing elements are
configured to sense
the light reflected by the top reflective stickers and output level signals;
the side reflective stickers are mounted on the side surfaces of the sprocket
wheel teeth,
each horizontal photoelectric sensing module includes a horizontal light
source and a
horizontal photoelectric sensing element, the horizontal light sources are
configured to emit
light toward the side reflective stickers, and the horizontal photoelectric
sensing elements are
configured to sense the light reflected by the side reflective stickers and
output level signals;
the data analysis module includes a lower computer and an industrial personal
computer,
the lower computer is configured to acquire level signals outputted by the
vertical photoelectric
sensing elements and the horizontal photoelectric sensing elements, and the
industrial personal
computer is configured to analyze the acquired level signals in order to
obtain the abrasion
conditions of the sprocket wheel teeth.
According to an aspect of the invention, there is provided a scraper conveyer
sprocket
wheel tooth abrasion monitoring device, characterized by comprising top
reflective stickers,
vertical photoelectric sensing modules, side reflective stickers, horizontal
photoelectric sensing
modules, and a data analysis module, wherein
the top reflective stickers are mounted on top surfaces of sprocket wheel
teeth, each
vertical photoelectric sensing module comprises a vertical light source and a
vertical
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2a
photoelectric sensing element, the vertical light sources are configured to
emit light toward the
top reflective stickers, and the vertical photoelectric sensing elements are
configured to sense
the light reflected by the top reflective stickers and output level signals;
the side reflective stickers are mounted on side surfaces of the sprocket
wheel teeth, each
horizontal photoelectric sensing module comprises a horizontal light source
and a horizontal
photoelectric sensing element, the horizontal light sources are configured to
emit light toward
the side reflective stickers, and the horizontal photoelectric sensing
elements are configured to
sense the light reflected by the side reflective stickers and output level
signals;
the data analysis module comprises a lower computer and an industrial personal
computer,
wherein the lower computer is configured to acquire level signals outputted by
the vertical
photoelectric sensing elements and the horizontal photoelectric sensing
elements, and the
industrial personal computer is configured to analyze the acquired level
signals in order to
obtain abrasion conditions of the sprocket wheel teeth. ;
characterized by comprising the following steps:
firstly, a sampling frequency is allocated to both the vertical photoelectric
sensing modules
and horizontal photoelectric sensing modules, the vertical photoelectric
sensing modules are
set to output high levels when receiving light reflected by the top reflective
stickers, and
otherwise output low level, and the horizontal photoelectric sensing modules
are set to output
high levels when receiving light reflected by the side reflective stickers,
and otherwise output
low levels;
secondly, when sprocket wheel teeth do not have any abrasion, original
dimensions Lõ_0
of corresponding parts of end surfaces of crests of the sprocket wheel teeth
are measured,
meanwhile, a high level length LD_o outputted by the vertical photoelectric
sensing module
and a low level L2_0 outputted by the horizontal photoelectric sensing module
which
correspond to a single sprocket wheel tooth are acquired, and a ratio factor
kõ L0_0 41_0 is
calculated;
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then, when sprocket wheel tooth abrasion loss is measured actually, it is
assumed that the
high level length outputted by each vertical photoelectric sensing module is
and the low level
length outputted by each horizontal photoelectric sensing module is when a
single sprocket
wheel tooth passes, a ratio factor Ak = L2_042 is calculated, Ak = 1 if a
scraper conveyer
runs at constant speed, so is Ak defined as a correction factor to eliminate
effect of changing
rotational speed on sprocket wheel tooth abrasion loss measurement during
measurement;
= Akxknx 1 is calculated, and thereby sprocket wheel tooth abrasion
loss is
ALD = LD-0
finally, an abrasion threshold J of the sprocket wheel teeth is set, wherein
if the sprocket
wheel tooth abrasion loss is AL,, < J , the sprocket wheel teeth can be used
continuously and
normally; if the sprocket wheel tooth abrasion is A/0 J, and an abrasion
danger warning
signal is outputted.
Preferably, the top reflective stickers have the same shape as the top
surfaces of the
sprocket wheel teeth, and the side reflective stickers have the same shape as
the side surfaces
of the sprocket wheel teeth.
Preferably, both the vertical light sources and the horizontal light sources
are point
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light sources.
Preferably, each vertical photoelectric sensing element is shaped like a
circular arc, and
the horizontal photoelectric sensing elements have the same shape as the side
reflective
stickers.
Preferably, each of the vertical photoelectric sensing modules and the
horizontal
photoelectric sensing modules also includes a signal conditioning unit for
amplifying and
filtering the outputted level signals.
Also disclosed is a scraper conveyer sprocket wheel tooth abrasion monitoring
method
based on the above-mentioned monitoring device, which includes the following
steps:
firstly, the same sampling frequency is allocated to vertical photoelectric
sensing
modules and horizontal photoelectric sensing modules, the vertical
photoelectric sensing
modules are set to output high levels when receiving light reflected by the
top reflective
stickers, and otherwise output low levels, and the horizontal photoelectric
sensing modules
are set to output high levels when receiving light reflected by the side
reflective stickers,
and otherwise output low levels;
secondly, when sprocket wheel teeth do not have any abrasion, the original
dimensions
LD 0 of corresponding parts of the end surfaces of the crests of the sprocket
wheel teeth
are measured, meanwhile, a high level length L
outputted by the vertical photoelectric
sensing module and a low level 1.2 0 outputted by the horizontal photoelectric
sensing
module which correspond to a single sprocket wheel tooth are acquired, and a
ratio factor
I'D =4_0/4 0 is calculated;
then, when sprocket wheel tooth abrasion loss is measured actually, it is
assumed that
the high level length outputted by each vertical photoelectric sensing module
is I, and
the low level length outputted by each horizontal photoelectric sensing module
is L, ,
when a single sprocket wheel tooth passes, a ratio factor Ak = L2 0/4 is
calculated,
Ak =1 if a scraper conveyer runs at constant speed, so Ak is defined as a
correction
factor to eliminate the affection of changing rotational speed on sprocket
wheel tooth
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abrasion loss measurement during measurement; L, = Akx1c0x L, is calculated,
and
thereby sprocket wheel tooth abrasion loss is AL, ¨ LI) 0 ;
finally, an abrasion threshold J of the sprocket wheel teeth is set, the
sprocket wheel
tooth abrasion loss does not go beyond the limit when AL, < , and therefore
the sprocket
wheel teeth can be used continuously and normally; the sprocket wheel tooth
abrasion loss
goes beyond the limit when ALõ J, and an abrasion danger warning signal is
outputted.
Beneficial effects: After the abrasion of the sprocket wheel teeth occurs, the
structural
dimensions of the sprocket wheel teeth in the running direction of the chains
of the scraper
conveyer become small, and the present invention acquires thickness data
reflecting the
sprocket wheel teeth in real time through high and low level signal lengths by
a
photoelectric sensing principle, and acquires real-time sprocket wheel tooth
abrasion loss
by comparing with the original thickness value. The present invention can
implement the
real-time measurement of sprocket wheel tooth abrasion loss to prevent
equipment
abnormality, damage and economic loss as the result of the skipping of chains
of a scraper
conveyer caused by the severe abrasion of sprocket wheel teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. I is a structural schematic diagram of the present invention;
Fig. 2 is a schematic mounting diagram of vertical photoelectric sensing
modules of the
present invention;
Fig. 3 is a schematic mounting diagram of horizontal photoelectric sensing
modules of
the present invention;
Fig. 4 is a schematic system configuration diagram of the present invention.
In the drawings, I and 7 are horizontal photoelectric sensing modules, 2 is a
side
reflective sticker, 3 and 6 are vertical photoelectric sensing modules, 4 and
5 are top
reflective stickers, 8 is a left sprocket wheel, 9 is a right sprocket wheel,
10 is a data
analysis module, 11 is a vertical photoelectric sensing element, 12 is a
vertical light source,
13 is a horizontal photoelectric sensing element, and 14 is a horizontal light
source.
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DETAILED DESCRIPTION
The present invention is further explained in reference to the drawings.
As shown in Figs. 1, 2, 3 and 4, the present invention discloses a scraper
conveyer
sprocket wheel tooth abrasion monitoring device, which includes top reflective
stickers,
vertical photoelectric sensing modules, side reflective stickers, horizontal
photoelectric
sensing modules, and a data analysis module.
The top reflective stickers are mounted on the top surfaces of sprocket wheel
teeth, the
top reflective stickers have the same shape as the top surfaces of the
sprocket wheel teeth,
each vertical photoelectric sensing module includes a vertical light source
and a vertical
photoelectric sensing element, the vertical light sources are point light
sources, the vertical
light sources are configured to emit light toward the top reflective stickers,
each vertical
photoelectric sensing element is shaped like a circular arc, and the vertical
photoelectric
sensing elements are configured to sense the light reflected by the top
reflective stickers
and output level signals. Each vertical photoelectric sensing module also
includes a signal
conditioning unit for amplifying and filtering the outputted level signals. A
power supply
supplies electricity to the vertical light sources and the signal conditioning
units.
The side reflective stickers are mounted on the side surfaces of the sprocket
wheel
teeth, the side reflective stickers have the same shape as the side surfaces
of the sprocket
wheel teeth, each horizontal photoelectric sensing module includes a
horizontal light source
and a horizontal photoelectric sensing element, the horizontal light sources
are point light
sources, the horizontal light sources are configured to emit light toward the
side reflective
stickers, the horizontal photoelectric sensing elements have the same shape as
the side
reflective stickers, and the horizontal photoelectric sensing elements are
configured to sense
the light reflected by the side reflective stickers and output level signals.
Each horizontal
photoelectric sensing module also includes a signal conditioning unit for
amplifying and
filtering the outputted level signals. The power supply supplies electricity
to the horizontal
light sources and the signal conditioning units.
The data analysis module includes a lower computer and an industrial personal
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computer, the power supply supplies electricity to the lower computer and the
industrial
personal computer, the tower computer is configured to acquire level signals
outputted by
the vertical photoelectric sensing elements and the horizontal photoelectric
sensing
elements, and the industrial personal computer is configured to analyze the
acquired level
signals in order to obtain the abrasion conditions of the sprocket wheel
teeth.
In the present embodiment, a set of vertical photoelectric sensing modules and
top
reflective stickers and a set of horizontal photoelectric sensing modules and
side reflective
stickers are arranged at sprocket wheels corresponding to each of chains at
the head and tail
of a scraper conveyer. The vertical photoelectric sensing modules and the
horizontal
photoelectric sensing modules are mounted overhead through fixed tube supports
and the
like, and the sprocket wheel teeth and the chains which are opposite to the
spaces do not fit
each other when running; the side reflective stickers are respectively mounted
on the left
side surfaces of left sprocket wheel teeth and the right side surfaces of
right sprocket wheel
teeth, and the top reflective stickers are respectively mounted on the crests
of the left teeth
of a left sprocket wheel and the crests of the right teeth of a right sprocket
wheel.
The scraper conveyer carries out the conveyance of materials by means of the
rotating
sprocket wheels driving the chains to move; after the severe abrasion of the
sprocket wheel
teeth occurs, the skipping phenomenon of the chains will take place, causing
the tension
imbalance between the chains of the scraper conveyer, and ultimately,
failures, such as
chain breakage and scraper bending, are caused, affecting the normal running
of the scraper
conveyer and the effective implementation of the conveying function. After the
abrasion of
the sprocket wheel teeth occurs, the structural dimensions of the sprocket
wheel teeth in the
running direction of the chains of the scraper conveyer become small, and the
present
invention acquires thickness data reflecting the sprocket wheel teeth in real
time through
high and low level signal lengths by a photoelectric sensing principle, and
acquires
real-time sprocket wheel tooth abrasion loss by comparing with an original
thickness value.
Also disclosed is a scraper conveyer sprocket wheel tooth abrasion monitoring
method
based on the monitoring device, which includes the following steps:
firstly, the same sampling frequency is allocated to vertical photoelectric
sensing
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modules and horizontal photoelectric sensing modules, the vertical
photoelectric sensing
modules are set to output high levels when receiving light reflected by the
top reflective
stickers, and otherwise output low levels, and the horizontal photoelectric
sensing modules
are set to output high levels when receiving light reflected by the side
reflective stickers,
and otherwise output low levels;
secondly, when sprocket wheel teeth do not have any abrasion, the original
dimensions
LD 0 of corresponding parts of the end surfaces of the crests of the sprocket
wheel teeth
are measured, meanwhile, a high level length Li outputted by the vertical
photoelectric
sensing module and a low level 1.2 õ outputted by the horizontal photoelectric
sensing
module which correspond to a single sprocket wheel tooth are acquired, and a
ratio factor
;co= LD 04,0 is calculated;
then, when sprocket wheel tooth abrasion loss is measured actually, it is
assumed that
the high level length outputted by each vertical photoelectric sensing module
is 4,1 and
the low level length outputted by each horizontal photoelectric sensing module
is L2,
when a single sprocket wheel tooth passes, a ratio factor Ak = L2 042 t is
calculated,
Ak =1 if a scraper conveyer runs at constant speed, so Ak is defined as a
correction
factor to eliminate the affection of changing rotational speed on sprocket
wheel tooth
abrasion loss measurement during measurement; LD Akxkpx
LI is calculated, and
thereby sprocket wheel tooth abrasion loss is ALI, = LD LD 1;
finally, an abrasion threshold J of the sprocket wheel teeth is set, the
sprocket wheel
tooth abrasion loss does not go beyond the limit when AL, <f , and therefore
the sprocket
wheel teeth can be used continuously and normally; the sprocket wheel tooth
abrasion loss
goes beyond the limit when AL, 3, and an abrasion danger warning signal is
outputted.
What is described above is merely the preferred embodiments of the present
invention,
it should be pointed out that under the premise of not departing from the
principle of the
present invention, those skilled in the art can also make a plurality of
improvements and
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embellishments, and these improvements and embellishments should also be
regarded as
the protection scope of the present invention.
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