低功耗刮板输送机张力无线监测系统设计
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摘要
针对现有刮板输送机刮板链张力监测系统存在易损坏、数据无法实时传输、精度较差和功耗过大等问题,设计了一套低功耗刮板输送机张力无线监测系统及适用于该系统的无线通信布置方案。该系统封装于刮板和中板内部,不会受到矿石的冲击和矿水的侵蚀,封装的同时加工出可供电磁波通过的信号溢出口,使张力数据通过无线方式传输。封装在下压板内的张力采集装置通过粘贴在刮板链上的应变片获取张力信息,张力信息通过无线方式发送给封装在中板内的数据接收装置,数据接收装置再将数据上传至上位机或LCD显示器,实现张力的实时监测。实验结果表明,该系统通过与改造过的刮板输送机部件配合,可避免矿石、矿水的冲击、侵蚀和井下电磁的干扰,完成在恶劣环境下刮板链张力的实时监测任务,有效解决了现有刮板链张力监测系统在恶劣环境下易失效、张力数据不能实时上传等问题;引入接近开关和休眠机制的张力采集装置的能耗可降至最低,休眠状态下的功耗约为工作状态的1/40,大大延长了系统使用寿命。
In view of problems that existing tension monitoring system of scraper chain of scraper conveyor is easy to damage,cannot transmit data in real-time,accuracy is poor and power consumption is excessive,a wireless tension monitoring system with low-power consumption of scraper conveyors and wireless communication layout scheme suitable for the system were designed.The system is encapsulated in the scraper and the middle plate,which will not be impacted by ore and eroded by mine water.At the same time,a signal overflow outlet can be processed for electromagnetic wave to pass through,so that the tension data can be transmitted wirelessly.The tension acquisition device encapsulated in the bottom pressing plate obtains tension information through the strain gauge pasted on the scraper chain,tension information is transmitted wirelessly to the data receiving device encapsulated in the middle plate,which then uploads the data to the upper computer or LCD display to realize real-time tension monitoring.The experiment results show that through cooperation with modified parts of the scraper conveyor,the systemcan avoid impact of mineral,erosion of mineral water and electromagnetic interference,and can complete real-time tension monitoring in harsh environments,and can effectively solve the problem that existing scraper chain tension monitoring system is easy to failure and can't upload real-time tension data in harsh environments.The energy consumption of the tension acquisition device which introduces proximity switch and dormancy mechanism is reduced to the minimum,and the power consumption in dormancy state is about 1/40 of that in working state,which greatly extends service life of the system.
In view of problems that existing tension monitoring system of scraper chain of scraper conveyor is easy to damage,cannot transmit data in real-time,accuracy is poor and power consumption is excessive,a wireless tension monitoring system with low-power consumption of scraper conveyors and wireless communication layout scheme suitable for the system were designed.The system is encapsulated in the scraper and the middle plate,which will not be impacted by ore and eroded by mine water.At the same time,a signal overflow outlet can be processed for electromagnetic wave to pass through,so that the tension data can be transmitted wirelessly.The tension acquisition device encapsulated in the bottom pressing plate obtains tension information through the strain gauge pasted on the scraper chain,tension information is transmitted wirelessly to the data receiving device encapsulated in the middle plate,which then uploads the data to the upper computer or LCD display to realize real-time tension monitoring.The experiment results show that through cooperation with modified parts of the scraper conveyor,the systemcan avoid impact of mineral,erosion of mineral water and electromagnetic interference,and can complete real-time tension monitoring in harsh environments,and can effectively solve the problem that existing scraper chain tension monitoring system is easy to failure and can't upload real-time tension data in harsh environments.The energy consumption of the tension acquisition device which introduces proximity switch and dormancy mechanism is reduced to the minimum,and the power consumption in dormancy state is about 1/40 of that in working state,which greatly extends service life of the system.
引文
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[12]郭山红,孙锦涛,谢仁宏,等.电磁波穿透墙体的衰减特性[J].强激光与粒子束,2009,21(1):113-117.
[13]周琦,刘新芽.多层介质中电磁波的反射与透射[J].南昌大学学报(理科版),2003,27(1):37-44.ZHOU Qi,LIU Xinya.The reflection and transmission of electromagnetic wave in multilayer media[J].Journal of Nanchang University(Natural Science),2003,27(1):37-44.
[14]常慧,张玉强,吕忠亭,等.电磁波斜入射分层介质问题FDTD分析[J].电子测量技术,2015,38(10):140-143.CHANG Hui,ZHANG Yuqiang,LYU Zhongting,et al.FDTD analysis for electromagnetic wave by layered medium problem under oblique incidence condition[J].Electronic Measurement Technology,2015,38(10):140-143.
[15]焦瑜呈.海水中电磁波特性的分析与研究[J].舰船电子工程,2018,38(8):176-179.JIAO Yucheng.Analysis and research of the electromagnetic properties of seawater[J].Ship Electronic Engineering,2018,38(8):176-179.
[2]LI Junxia,LIANG Shaowei.Friction and wear of the middle trough in scraper conveyors[J].Industrial Lubrication and Tribology,2018,70(6):1072-1077.
[3]蔡柳,王学文,王淑平,等.煤散料在刮板输送机中部槽中的运动分布特征与作用力特性[J].煤炭学报,2016,41(增刊1):247-252.CAI Liu,WANG Xuewen,WANG Shuping,et al.Motion characteristics and force properties of bulk coal in middle pan of scraper conveyor[J].Journal of China Coal Society,2016,41(S1):247-252.
[4]谢苗,毛君,许文馨.重型刮板输送机故障载荷工况与结构载荷工况的动力学仿真研究[J].中国机械工程,2012,23(10):1200-1204.XIE Miao,MAO Jun,XU Wenxin.Dynamics simulation of heavy scraper conveyor in working condition of failure-load and structural load[J].China Mechanical Engineering,2012,23(10):1200-1204.
[5]张瑞昭.煤矿各类废水处理及综合利用途径[J].煤炭科学技术,2018,46(增刊1):268-270.ZHANG Ruizhao.Various types of wastewater treatment and comprehensive utilization methods in coal mines[J].Coal Science and Technology,2018,46(S1):268-270.
[6]蔡文飞,雷志鹏,宋建成,等.矿用刮板输送机链条张紧力监控技术现状及其发展方向[J].工矿自动化,2018,44(11):25-31.CAI Wenfei,LEI Zhipeng,SONG Jiancheng,et al.Present situation and development direction of monitoring technology for chain tension of mine-used scraper conveyor[J].Industry and Mine Automation,2018,44(11):25-31.
[7]任威,卢明立,杨志明,等.重型刮板输送机张力检测系统设计[J].工矿自动化,2017,43(3):6-9.REN Wei,LU Mingli,YANG Zhiming,et al.Design of tension testing system of heavy scraper conveyor[J].Industry and Mine Automation,2017,43(3):6-9.
[8]齐秀飞,张佩,郝志勇,等.刮板输送机链条张力检测系统研究[J].机械强度,2017,39(3):534-539.QI Xiufei,ZHANG Pei,HAO Zhiyong,et al.Study on scraper conveyor or chain tension testing system[J].Journal of Mechanical Strength,2017,39(3):534-539.
[9]张强,王海舰,毛君,等.基于压电振动俘能的自供电刮板输送机张力检测系统[J].传感技术学报,2015,28(9):1335-1340.ZHANG Qiang,WANG Haijian,MAO Jun,et al.Self-powered tension testing system for scraper conveyor based on piezoelectric vibration energy harvested[J].Chinese Journal of Sensors and Actuators,2015,28(9):1335-1340.
[10]骆铁楠.刮板输送机圆环链无线张力传感器研制[J].工矿自动化,2018,44(9):77-83.LUO Tienan.Development of wireless tension sensor of round link chain of scraper conveyor[J].Industry and Mine Automation,2018,44(9):77-83.
[11]何绪文,李福勤.煤矿矿井水处理新技术及发展趋势[J].煤炭科学技术,2010,38(11):17-22.HE Xuwen,LI Fuqin.New technology and development tendency of mine water treatment[J].Coal Science and Technology,2010,38(11):17-22.
[12]郭山红,孙锦涛,谢仁宏,等.电磁波穿透墙体的衰减特性[J].强激光与粒子束,2009,21(1):113-117.
[13]周琦,刘新芽.多层介质中电磁波的反射与透射[J].南昌大学学报(理科版),2003,27(1):37-44.ZHOU Qi,LIU Xinya.The reflection and transmission of electromagnetic wave in multilayer media[J].Journal of Nanchang University(Natural Science),2003,27(1):37-44.
[14]常慧,张玉强,吕忠亭,等.电磁波斜入射分层介质问题FDTD分析[J].电子测量技术,2015,38(10):140-143.CHANG Hui,ZHANG Yuqiang,LYU Zhongting,et al.FDTD analysis for electromagnetic wave by layered medium problem under oblique incidence condition[J].Electronic Measurement Technology,2015,38(10):140-143.
[15]焦瑜呈.海水中电磁波特性的分析与研究[J].舰船电子工程,2018,38(8):176-179.JIAO Yucheng.Analysis and research of the electromagnetic properties of seawater[J].Ship Electronic Engineering,2018,38(8):176-179.