CN102183330A - Device and method for monitoring tensioning states of scraper conveyor chains - Google Patents
Device and method for monitoring tensioning states of scraper conveyor chains Download PDFInfo
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Abstract
The invention discloses a device and a method for monitoring tensioning states of scraper conveyor chains and relates to the device and method for monitoring the tensioning states of scraper conveyor chains in coal mines. The device is characterized in that the device comprises scraper conveyor head and scraper conveyor tail motor power converters, chain suspension quantity transducers, scraper conveyor tail telescopic cylinder pressure sensors, signal conditioning units, primary fusion centers and a chain state display controller; the scraper conveyer head and tail are provided with the power converters respectively; the two telescopic cylinders disposed on the scraper conveyer tail in a parallel manner are provided with the pressure transducers respectively; and separation points of scraper conveyor head chain wheels and two chains are provided with the suspension quantity transducers. The signal conditioning units completes the preprocessing, such as amplification and filtering of the output signals of the transducers, the primary fusion centers perform primary processing of the transducer data of same types, the chain state display controller completes a second-step fusion of the chain tension characteristic information of different types and indicator lights show the chain tensioning states. The device and method improve accuracy and reliability of the monitoring, protect safety of the chains and accordingly prolong the service lifetimes of the chains.
Description
Technical field
The present invention relates to a kind of coal mine lower scraping plate conveyor chain state monitoring apparatus and method, especially a kind of scraper conveyer chain tensioning state monitoring device and method.
Background technology
Scraper conveyor is one of key equipment of coal mine fully-mechanized mining working.In the scraper conveyor course of work, reason such as chain tension can be non-constant owing to load, hydraulic support passing constantly changes, and causing chain was not that pine is exactly a tension.Chain is loose excessively, can destroy the engagement of sprocket wheel and chain, causes chain accumulation kink; The chain tension can strengthen power attenuation, causes the element excessive wear.In case the stroke of chain exceeds allowed band, the life-span of chain and the normal operation of scraper conveyor will be had a strong impact on.Therefore, the monitoring of scraper conveyer chain tensioning state is to guarantee that scraper conveyor is in optimal operational condition all the time, guarantees that whole colliery is highly efficient and productive, the gordian technique of safety in production.
At present, domestic fully-mechanized mining working is to the actual monitoring of scraper conveyer chain tensioning state, mainly be to rely on use experience, by the degree of tightness situation in the manual observation chain operational process, head sprocket wheel friction size, make qualitative conclusions with the situation of dangling, scraper chain and the chute of following chain burble point place chain.This experience monitoring method varies with each individual, and has significant limitation.
External research starting aspect the scraper conveyer chain tension monitoring is morning, but because the direct monitoring of chain tension has certain difficulty.Therefore, in the prior art, be to obtain the chain tension value indirectly mostly, mainly formed the method for following three kinds of monitoring chain tensions:
1, utilizes power-length tension relation monitoring chain tension.This technology is Britain MECO company (now be renamed as international longwell company) exploitation, utilize the particular kind of relationship between scraper conveyer chain tension force and the institute's wasted work rate, installation power transmitter on head, tail motor obtains chain tension indirectly by measuring institute's wasted work rate.
2, utilize overhang-length tension relation monitoring chain tension.This technology is the exploitation of German Westphalia Bei Kaoruite company.Utilize the overhang at special sensor monitoring chain minimum tension point place to obtain chain tension indirectly.
3, utilize tail telescopic oil cylinder pressure-length tension relation monitoring chain tension.This technology is Britain Jia Like company (now incorporated into international longwell company) exploitation, and setting pressure sensor in the tail telescopic oil cylinder obtains chain tension indirectly by the force value of monitoring telescopic adjustment tension force oil cylinder.
More than the monitoring method of three kinds of scraper conveyer chain tension force all be to utilize single information source to carry out independent monitoring, in case sensor breaks down, then can't provide information to controller, cause system not work.In addition, lack the overall treatment of multiple information and effectively utilization from the monitoring method of single angle to scraper conveyer chain tension force, thereby in the defective that all exists aspect reliability, accuracy and the practicality of monitoring in various degree.
Summary of the invention
The objective of the invention is to provide a kind of scraper conveyer chain tensioning state monitoring device and method, solution lacks the overall treatment of multiple information and effectively utilization from the monitoring method of single angle to scraper conveyer chain tension force, thereby all has the problem of defective in various degree aspect reliability, accuracy and the practicality of monitoring.
The object of the present invention is achieved like this: the device of this chain tension status monitoring is: comprise the head power transducer, the head drive motor, the head fluid coupling, the head speed reduction unit, the tail power transducer, the tail drive motor, the tail fluid coupling, the tail speed reduction unit, the tail chain wheel assembly, the first tail telescopic oil cylinder, the second tail telescopic oil cylinder, first pressure transducer, second pressure transducer, scraper plate, first chain, second chain, the head chain wheel assembly, the first overhang sensor, the second overhang sensor, the signal condition unit, elementary fusion center and chain state display controller, the head power transducer is connected on the head drive motor, the head drive motor is connected with the head speed reduction unit by the head fluid coupling, and the head chain wheel assembly is connected with the head speed reduction unit; The tail power transducer is connected on the tail drive motor, and the tail drive motor is connected with the tail speed reduction unit by the tail fluid coupling, and the tail chain wheel assembly is connected with the tail speed reduction unit; Between head chain wheel assembly and tail chain wheel assembly, be connected with first chain and second chain, on first chain and second chain, be provided with scraper plate; Be connected with the first overhang sensor and the second overhang sensor at head chain wheel assembly place, be connected with first pressure transducer and second pressure transducer at nearly tail chain wheel assembly place; Head power transducer, tail power transducer, first pressure transducer, second pressure transducer, the first overhang sensor and the second overhang sensor all are connected with elementary fusion center by the signal condition unit, and elementary fusion center is connected with chain state display controller.
The method of chain tension status monitoring is: the head power transducer, the tail power transducer, first pressure transducer, second pressure transducer, the first overhang sensor, the second overhang signal of sensor is amplified through the signal condition unit, pre-service such as filtering, pretreated same type sensing data enters elementary fusion center, elementary fusion center utilizes its A/D converter that carries that sensing data is converted to digital signal, adopt corresponding fuzzy nearness algorithm to do rough handling, export preliminary fusion results, send into chain state display controller then, chain state display controller merges carry out secondary from the dissimilar chain tension characteristic information of elementary fusion center, shows the chain tension state by five pilot lamp at last;
The fusion process of described fuzzy nearness algorithm comprises:
(1) to monitoring the same type sensor output data of same parameter
, ask its mean value
And variance
(2) with measured value
And mean value
Obfuscation obtains
With
(3) calculate fuzzy nearness between each sensing data and the mean value
, basis again
Relative weighting when asking each sensing data to merge
(4) according to formula
, try to achieve the elementary fusion results of same parameter.
Described elementary fusion center has a single-chip microcomputer, and the model of this single-chip microcomputer is 80C196KB, for carrying the single-chip microcomputer of A/D converter, converts the sensor signal after the conditioning to digital signal, calls the fuzzy nearness algorithm then and carries out elementary fusion.
Beneficial effect, owing to adopted such scheme, scraper conveyor adopts head, tail constant power double motor to drive.Appropriate location difference installation power transmitter on scraper conveyor head, tail motor, appropriate location difference setting pressure sensor is installed the overhang sensor respectively in the appropriate location, burble point place of head sprocket wheel and two chains in the telescopic oil cylinder of two parallel placements of tail.All the sensors links to each other with separately signal condition unit, finishes the pre-service such as amplification, filtering of sensor output signal; Signal processing unit links to each other with the hyperchannel A/D translation interface that elementary fusion center carries, and is digital signal with analog signal conversion; The data of the same type sensor after elementary fusion center is changed A/D are carried out initial analysis and are handled; Chain state display controller carries out overall treatment to dissimilar chain tension characteristic information, shows the chain tension state by five pilot lamp at last.
Use multi-sensor information fusion technology, energy will be from scraper conveyor head, tail power of motor transmitter, and the multidimensional information of the first overhang sensor, the second overhang sensor and the first tail telescopic oil cylinder, the second tail telescopic oil cylinder pressure transducer effectively merges.Comprise three types of sensors in the device of the present invention, every class sensor is provided with two monitoring points, therefore the blended data fusion structure that adopts two-stage to merge.Three elementary fusion centers all adopt the fuzzy nearness algorithm that the Monitoring Data of same type sensor is carried out analyzing and processing, export preliminary fusion results, chain state display controller adopts grey correlation analysis as the secondary blending algorithm, dissimilar chain tension characteristic information from three elementary fusion centers are carried out overall treatment, can export the chain tension state of scraper conveyor more accurate, more reliably, eliminate the limitation of traditional single-sensor monitoring, shown the chain tension state by five pilot lamp at last.
Solved from the monitoring method of single angle and lacked the overall treatment of multiple information and effectively utilization to scraper conveyer chain tension force, thereby, reached purpose of the present invention all having the problem of defective in various degree aspect reliability, accuracy and the practicality of monitoring.
Advantage: a kind of scraper conveyer chain tensioning state monitoring device can be to the monitoring of fully mechanized coal face scraper conveyer chain tension force under the coal mine.Adopt multi-sensor information fusion technology, overcome the defective of traditional single-sensor monitoring method, can be more accurate; export the chain tensioning state more reliably; the safety of protection chain prolongs the serviceable life of chain, thereby has guaranteed the safe operation of scraper conveyor.
Description of drawings
Fig. 1 is a structural drawing of the present invention.
Fig. 2 is a principle of work block diagram of the present invention.
Among the figure: 1, head power transducer; 2, head drive motor; 3, head fluid coupling; 4, head speed reduction unit; 5, tail power transducer; 6, tail drive motor; 7, tail fluid coupling; 8, tail speed reduction unit; 9, tail chain wheel assembly; 10, the first tail telescopic oil cylinder; 11, the second tail telescopic oil cylinder; 12, first pressure transducer; 13, second pressure transducer; 14, scraper plate; 15, first chain; 16, second chain; 17, head chain wheel assembly; 18, the first overhang sensor; 19, the second overhang sensor; 20, signal condition unit; 21, elementary fusion center; 22, chain state display controller.
Embodiment
Embodiment 1: the device of this chain tension status monitoring is: comprise head power transducer 1, head drive motor 2, head fluid coupling 3, head speed reduction unit 4, tail power transducer 5, tail drive motor 6, tail fluid coupling 7, tail speed reduction unit 8, tail chain wheel assembly 9, the first tail telescopic oil cylinder 10, the second tail telescopic oil cylinder 11, first pressure transducer 12, second pressure transducer 13, scraper plate 14, first chain 15, second chain 16, head chain wheel assembly 17, the first overhang sensor 18, the second overhang sensor 19, signal condition unit 20, elementary fusion center 21 and chain state display controller 22, head power transducer 1 is connected on the head drive motor 2, head drive motor 2 is connected with head speed reduction unit 4 by head fluid coupling 3, and head chain wheel assembly 17 is connected with head speed reduction unit 4; Tail power transducer 5 is connected on the tail drive motor 6, and tail drive motor 6 is connected with tail speed reduction unit 8 by tail fluid coupling 7, and tail chain wheel assembly 9 is connected with tail speed reduction unit 8; Between head chain wheel assembly 17 and tail chain wheel assembly 9, be connected with first chain 15 and second chain 16, on first chain 15 and second chain 16, be provided with scraper plate 14; Be connected with the first overhang sensor 18 and the second overhang sensor 19 at head chain wheel assembly 17 places, be connected with first pressure transducer 12 and second pressure transducer 13 at nearly tail chain wheel assembly 9 places; Head power transducer 1, tail power transducer 5, first pressure transducer 12, second pressure transducer 13, the first overhang sensor 18 all are connected with elementary fusion center 21 by signal condition unit 20 with the second overhang sensor 19, and elementary fusion center 21 is connected with chain state display controller 22.
Described signal condition unit 20 is an XA90-BZ2704 type program control signal conditioner, is the commercially available prod, must place in the armored cassette during use.
The method of chain tension status monitoring is: the head power transducer, the tail power transducer, first pressure transducer, second pressure transducer, the first overhang sensor, the second overhang signal of sensor is amplified through the signal condition unit, pre-service such as filtering, pretreated same type sensing data enters elementary fusion center, elementary fusion center utilizes its A/D converter that carries that sensing data is converted to digital signal, adopt corresponding fuzzy nearness algorithm to do rough handling, export preliminary fusion results, send into chain state display controller then, chain state display controller merges carry out secondary from the dissimilar chain tension characteristic information of elementary fusion center, shows the chain tension state by five pilot lamp at last.
The fusion process of described fuzzy nearness algorithm comprises:
(1) to monitoring the same type sensor output data of same parameter
, ask its mean value
And variance
(2) with measured value
And mean value
Obfuscation obtains
With
(3) calculate fuzzy nearness between each sensing data and the mean value
, basis again
Relative weighting when asking each sensing data to merge
(4) according to formula
, try to achieve the elementary fusion results of same parameter.
Described elementary fusion center has a single-chip microcomputer, and the model of this single-chip microcomputer is 80C196KB, for carrying the single-chip microcomputer of A/D converter, converts the sensor signal after the conditioning to digital signal, calls the fuzzy nearness algorithm then and carries out elementary fusion.
In Fig. 1, scraper conveyer chain tensioning state monitoring device based on multi-sensor information fusion of the present invention, mainly by head power transducer (1), tail power transducer (5), the first overhang sensor (18), the second overhang sensor (19), tail first pressure transducer (12), second pressure transducer (13), signal condition unit (20), elementary fusion center (21) and chain state display controller (22) are formed.
Difference fitting machine greatest service rate transmitter, tail power transducer on scraper conveyor head, tail motor, first pressure transducer, second pressure transducer are installed respectively in the telescopic oil cylinder of two parallel placements of tail, the first overhang sensor, the second overhang sensor are installed respectively at the burble point place of head sprocket wheel and two chains.All the sensors links to each other with separately signal condition unit, finishes the pre-service such as amplification, filtering of sensor output signal; Signal processing unit links to each other with the hyperchannel A/D translation interface that elementary fusion center carries, and is digital signal with analog signal conversion; The data of the same type sensor after elementary fusion center is changed A/D are carried out initial analysis and are handled; Chain state display controller carries out overall treatment to dissimilar chain tension characteristic information, shows the chain tension state by five pilot lamp at last.
The blended data fusion structure that adopts two-stage to merge.
Described head power transducer 1, tail power transducer 5, first pressure transducer 12, second pressure transducer 13, the first overhang sensor 18, the output signal of the second overhang sensor 19 is amplified through signal condition unit 20, pre-service such as filtering, the data of pretreated same type sensor enter elementary fusion center 21, elementary fusion center 21 utilizes its A/D converter that carries that sensing data is converted to digital signal, adopt corresponding blending algorithm to do rough handling, export preliminary fusion results, send into chain state display controller 22 then, 22 pairs of dissimilar chain tension characteristic information from three elementary fusion centers 21 of chain state display controller are carried out secondary and are merged, and the chain tension state that at last overall treatment is obtained shows by five pilot lamp.
Described chain state display controller adopts the secondary blending algorithm of grey correlation analysis as dissimilar chain tension characteristic information.Utilize the scraper conveyer chain tension characteristic vector and the grey relational grade of standard feature vector to carry out the chain tension signature analysis, finally the degree of association is sorted, according to the degree of association
Size provide the chain tension state.
Five kinds of states of the corresponding chain of described scraper conveyer chain tension force standard feature vector: loose excessively, pine is suitable, tight and tension.
Introduce the concrete course of work of the present invention below in conjunction with accompanying drawing 2:
1, after scraper conveyor starts, at first to the power of head drive motor 2, tail drive motor 6, the pressure of tail first telescopic oil cylinder 10, second telescopic oil cylinder 11 and first chain 15, second chain 16 detect with the overhang at head chain wheel assembly 17 burble point places;
2, the pre-service such as amplification, filtering of Monitoring Data are finished in the Monitoring Data entering signal conditioning unit 20 of each sensor output;
3, enter the hyperchannel A/D translation interface that elementary fusion center 21 carries through pretreated each sensor monitors data, original analog signal is converted to the digital signal that to be discerned by processor;
4, elementary fusion center is a core with 16 single-chip microcomputer 80C196KB of INTEL Corp., carries 8 path 10 position A/D converters, adopts the fuzzy nearness algorithm as elementary blending algorithm, and the same type sensing data after the A/D conversion is handled.
With monitoring tail telescopic oil cylinder pressure is example, and the fusion process of fuzzy nearness algorithm is described:
1), at first to the output data of tail telescopic oil cylinder first pressure transducer and second pressure transducer
(
), ask its mean value
And variance
2), with Monitoring Data
(
) and mean value
Carry out obfuscation respectively, obtain
(
) and
3), calculate fuzzy nearness between each pressure sensor data and the mean value
(
), basis again
(
) relative weighting when asking each pressure sensor data to merge
(
);
4), at last, according to formula
, try to achieve the elementary fusion results of tail telescopic oil cylinder pressure.
Using such method can obtain the preliminary fusion results of scraper conveyor head, tail motor power (output) and chain and head sprocket wheel burble point place overhang.
5, the preliminary fusion results of the dissimilar chain tension characteristic information (power of motor, telescopic oil cylinder pressure and chain overhang) that three elementary fusion centers 21 are exported is delivered to chain state display controller 22.Chain state display controller is a core with the S3C44B0X ARM microprocessor of Samsung, adopts grey correlation analysis as blending algorithm.Utilize the scraper conveyer chain tension characteristic vector and the grey relational grade of standard feature vector to carry out the chain tension signature analysis, finally according to the degree of association
Size provide the chain tension state.
The process of grey correlation analysis is as follows: establish the chain tension proper vector
Be comparative sequences, wherein
Represent the overhang at motor power (output), telescopic oil cylinder pressure and chain and head sprocket wheel burble point place respectively.Chain tension standard feature vector
Be the system features reference sequences,
Correspond respectively to five kinds of states of chain: loose excessively, loose, suitable, tight, tension.
The value of the motor power (output) of correspondence, telescopic oil cylinder pressure and three kinds of characteristic parameters of chain overhang when representing chain to be in i kind state.Calculate chain tension feature vector, X and chain tension standard feature vector respectively
The degree of association
, obtain
, the degree of association is sorted, find out
In maximal value, can obtain the tensioning state of scraper conveyer chain.For example as if in five degrees of association
Maximum illustrates that then the chain state is loose excessively.
At last, chain state display controller 22 is handled the chain tension state obtain according to the secondary convergence analysis, lights corresponding status indicator lamp, can be in time provides foundation for the failure prediction of scraper chain.
Claims (3)
1. scraper conveyer chain tensioning state monitoring device, it is characterized in that: the device of this chain tension status monitoring is: comprise the head power transducer, the head drive motor, the head fluid coupling, the head speed reduction unit, the tail power transducer, the tail drive motor, the tail fluid coupling, the tail speed reduction unit, the tail chain wheel assembly, the first tail telescopic oil cylinder, the second tail telescopic oil cylinder, first pressure transducer, second pressure transducer, scraper plate, first chain, second chain, the head chain wheel assembly, the first overhang sensor, the second overhang sensor, the signal condition unit, elementary fusion center and chain state display controller, the head power transducer is connected on the head drive motor, the head drive motor is connected with the head speed reduction unit by the head fluid coupling, and the head chain wheel assembly is connected with the head speed reduction unit; The tail power transducer is connected on the tail drive motor, and the tail drive motor is connected with the tail speed reduction unit by the tail fluid coupling, and the tail chain wheel assembly is connected with the tail speed reduction unit; Between head chain wheel assembly and tail chain wheel assembly, be connected with first chain and second chain, on first chain and second chain, be provided with scraper plate; Be connected with the first overhang sensor and the second overhang sensor at head chain wheel assembly place, be connected with first pressure transducer and second pressure transducer at nearly tail chain wheel assembly place; Head power transducer, tail power transducer, first pressure transducer, second pressure transducer, the first overhang sensor and the second overhang sensor all are connected with elementary fusion center by the signal condition unit, and elementary fusion center is connected with chain state display controller.
2. a scraper conveyer chain tensioning state is monitored the dress method, it is characterized in that: the method for chain tension status monitoring is: the head power transducer, the tail power transducer, first pressure transducer, second pressure transducer, the first overhang sensor, the second overhang signal of sensor is amplified through the signal condition unit, pre-service such as filtering, pretreated same type sensing data enters elementary fusion center, elementary fusion center utilizes its A/D converter that carries that sensing data is converted to digital signal, adopt corresponding fuzzy nearness algorithm to do rough handling, export preliminary fusion results, send into chain state display controller then, chain state display controller merges carry out secondary from the dissimilar chain tension characteristic information of elementary fusion center, shows the chain tension state by five pilot lamp at last;
The fusion process of described fuzzy nearness algorithm comprises:
(1) to monitoring the same type sensor output data of same parameter
, ask its mean value
And variance
(2) with measured value
And mean value
Obfuscation obtains
With
(3) calculate fuzzy nearness between each sensing data and the mean value
, basis again
Relative weighting when asking each sensing data to merge
(4) according to formula
, try to achieve the elementary fusion results of same parameter.
3. scraper conveyer chain tensioning state monitoring device according to claim 1 and 2 and method, it is characterized in that: described elementary fusion center has a single-chip microcomputer, the model of this single-chip microcomputer is 80C196KB, for carrying the single-chip microcomputer of A/D converter, convert the sensor signal after the conditioning to digital signal, call the fuzzy nearness algorithm then and carry out elementary fusion.
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| CN102556602A (en) * | 2012-02-13 | 2012-07-11 | 北京天地玛珂电液控制***有限公司 | Scraper conveyor with chain tensioning system |
| CN104150188A (en) * | 2014-07-16 | 2014-11-19 | 中国矿业大学(北京) | Tension wireless detecting system for round-link chain of scraper conveyor |
| CN105784241A (en) * | 2016-03-07 | 2016-07-20 | 中国矿业大学 | Method for estimating chain tension of scraper plate conveyer |
| CN105928653A (en) * | 2016-05-17 | 2016-09-07 | 中国矿业大学 | Scraper conveyor chain tension monitoring device and method |
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| CN102556602A (en) * | 2012-02-13 | 2012-07-11 | 北京天地玛珂电液控制***有限公司 | Scraper conveyor with chain tensioning system |
| CN104150188A (en) * | 2014-07-16 | 2014-11-19 | 中国矿业大学(北京) | Tension wireless detecting system for round-link chain of scraper conveyor |
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| WO2017152670A1 (en) * | 2016-03-07 | 2017-09-14 | 中国矿业大学 | Method for estimating chain tension of scraper conveyor |
| CN105784241B (en) * | 2016-03-07 | 2018-04-13 | 中国矿业大学 | A kind of scraper conveyer chain tension force evaluation method |
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