Disclosure of Invention
The invention mainly aims to provide a monitoring device and a monitoring method, which are used for solving the problem that the force monitoring method in the prior art is not suitable for monitoring the force of a tubular belt conveyor in the noise generation process.
In order to achieve the aim, according to one aspect of the invention, a monitoring device is provided, which comprises a tubular belt conveyor, wherein the tubular belt conveyor comprises a frame, a pipe belt and a plurality of carrier rollers, the frame is provided with an avoidance hole, the pipe belt is arranged in the avoidance hole in a penetrating mode, the plurality of carrier rollers are arranged at intervals around the circumference of the pipe belt, the carrier rollers comprise carrier roller shafts and carrier roller bodies rotatably sleeved outside the carrier roller shafts, a plurality of groups of resistance strain pieces are arranged on the inner wall surfaces of the carrier roller bodies of the plurality of carrier rollers in a one-to-one correspondence mode and used for monitoring strain effects generated by the corresponding carrier roller bodies in the moving process, and an upper computer is connected with the plurality of groups of resistance strain pieces and used for receiving monitoring results of the resistance strain pieces of each group and calculating noise of the tubular belt conveyor according to the monitoring results.
The monitoring device comprises a strain regulator, a data acquisition card and an upper computer, wherein the strain regulator is connected with the resistance strain gauge and is used for receiving and amplifying a monitoring signal of the resistance strain gauge to generate an amplified signal, and the data acquisition card is connected with the strain regulator and the upper computer and is used for acquiring the amplified signal and transmitting the amplified signal to the upper computer.
The monitoring device further comprises a collecting ring, a first connecting wire and a second connecting wire, wherein the collecting ring comprises an outer ring and an inner ring, the outer ring is connected with the inner wall surface of the carrier roller body, the inner ring is connected with the carrier roller shaft, one end of the first connecting wire is connected with the outer ring, the other end of the first connecting wire is connected with the resistance strain gauge, one end of the second connecting wire is connected with the inner ring, and the other end of the second connecting wire is connected with the strain regulator.
Further, a first wire-releasing groove is formed in the outer peripheral surface of the roller shaft, and two ends of the first wire-releasing groove are respectively communicated with the inside and the outside of the roller so as to be used for avoiding the second connecting wire.
Further, each set of resistive strain gages is affixed to a respective roller body, and/or each set of resistive strain gages includes a plurality of resistive strain gages disposed in spaced relation about an axis of the respective roller shaft.
Further, the avoiding holes are hexagonal holes, the plurality of rollers comprise a first roller, a second roller, a third roller, a fourth roller, a fifth roller and a sixth roller which are arranged in one-to-one correspondence with six sides of the hexagonal holes, wherein the first roller, the second roller and the third roller are positioned below the pipe belt, the second roller and the third roller are respectively positioned on two opposite sides of the first roller, the fourth roller, the fifth roller and the sixth roller are positioned above the pipe belt, and the fifth roller and the sixth roller are respectively positioned on two opposite sides of the fourth roller.
The monitoring device further comprises a plurality of guide mounting parts which are arranged on the frame at intervals around the central line of the avoidance hole, a plurality of adjustable roller frames, a plurality of carrier rollers and a plurality of guide mounting parts, wherein the plurality of adjustable roller frames are arranged on the plurality of adjustable roller frames in a one-to-one correspondence manner, the plurality of adjustable roller frames are arranged on the plurality of guide mounting parts in a one-to-one correspondence manner and are detachably arranged on the plurality of guide mounting parts, and the positions of the corresponding carrier rollers relative to the pipe belt are adjusted by adjusting the positions of the adjustable roller frames on the corresponding guide mounting parts.
Further, the adjustable carrier roller frame includes the intermediate support plate and is close to two engaging lugs that the opposite ends of intermediate support plate set up respectively, and the direction installation department includes along the direction installation space of radial extension of piping ribbon, and the intermediate support plate is along being close to or keeping away from the direction of piping ribbon adjustable setting in the direction installation space and with direction installation department detachably be connected, two engaging lugs extend towards the direction of keeping away from the frame to be connected with the opposite ends of bearing roller respectively.
According to another aspect of the invention, a monitoring method is provided, which is suitable for the monitoring device, and the monitoring method comprises the steps of formulating a noise judging rule, controlling the movement of a tubular belt conveyor, observing the test contact state between a pipe belt and each carrier roller, collecting the test strain quantity of the corresponding carrier roller monitored by each group of resistance strain sheets, carrying out data processing on the test strain quantity to obtain the test stress of the corresponding carrier roller, carrying out simulation analysis on the tubular belt conveyor based on the test contact state between the pipe belt and each carrier roller and the test stress of each carrier roller to obtain the overall noise of the tubular belt conveyor, obtaining a preset noise range and a preset stress range of each carrier roller corresponding to the preset noise range according to a noise environment-friendly standard, monitoring working conditions in real time, controlling the normal work of the tubular belt conveyor, observing the real-time contact state between the pipe belt and each carrier roller, collecting the real-time strain quantity of the corresponding carrier roller monitored by each group of resistance strain sheets, carrying out data processing on the real-time strain quantity to obtain the real-time stress of the corresponding carrier roller, and comparing the real-time stress of each carrier roller with the preset stress range to judge whether the overall noise of the tubular belt conveyor is in the preset noise range.
Further, the calculation formula of the stress of the carrier roller comprises: Wherein U is the voltage value measured by the resistance strain gauge, U1 is the reference zero drift voltage, K is the sensitivity coefficient of the resistance strain gauge, U0 is the bridge voltage of the bridge between the second connecting wire connected with the resistance strain gauge and the strain regulator, n is the bridge arm number of the bridge, KS is the gain coefficient of the strain regulator, and E is the elastic modulus of the roller body.
Further, the monitoring method comprises the steps of controlling a working state signal lamp of the tubular belt conveyor to display green when the contact state between the tubular belt and each carrier roller is free of obvious abnormality and the real-time overall noise of the tubular belt conveyor is within a preset noise range, controlling the working state signal lamp of the tubular belt conveyor to display yellow when the contact state between the tubular belt and each carrier roller is obvious abnormality and the real-time overall noise of the tubular belt conveyor is within the preset noise range, and controlling the working state signal lamp of the tubular belt conveyor to display red when the real-time overall noise of the tubular belt conveyor exceeds the preset noise range. .
The monitoring device comprises a tubular belt conveyor, wherein the tubular belt conveyor comprises a frame, a pipe belt and a plurality of carrier rollers, avoidance holes are formed in the frame, the pipe belt is arranged in the avoidance holes in a penetrating mode, the carrier rollers are arranged at intervals around the circumference of the pipe belt, the carrier rollers comprise carrier roller shafts and carrier roller bodies rotatably sleeved outside the carrier roller shafts, a plurality of groups of resistance strain gauges are arranged on the inner wall surfaces of the carrier roller bodies of the carrier rollers in a one-to-one correspondence mode and used for monitoring strain effects generated by the corresponding carrier roller bodies in the moving process, and an upper computer is connected with the plurality of groups of resistance strain gauges and used for receiving monitoring results of the resistance strain gauges and calculating noise of the tubular belt conveyor according to the monitoring results. Therefore, the invention adopts the resistance strain gauge to monitor the strain effect of the carrier roller, the cost is far lower than that of a non-contact sensor, the invention has better adaptability to components with lower precision such as the carrier roller, the size of the contact force of each carrier roller can be directly obtained by monitoring the strain effect generated by each carrier roller in the motion process, the contact state between a pipe belt and each carrier roller is obtained, the carrier roller with obviously abnormal contact state is found, and the risk judgment can be carried out on the motion noise of the pipe belt conveyor based on the noise early warning criterion of the pipe belt conveyor formulated by the contact state, thereby being beneficial to the adjustment of the installation position of the carrier roller, and solving the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the pipe belt conveyor in the noise generation process.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application. In the drawings:
Fig. 1 shows a schematic structural diagram of a monitoring device according to the invention;
Fig. 2 shows a cross-sectional view of a carrier roller of the tubular belt conveyor of the monitoring device shown in fig. 1 in one direction;
Fig. 3 shows a cross-sectional view of the idler of fig. 2 in another direction;
fig. 4 shows a distribution diagram of the positions of a plurality of idlers on a frame of the tubular belt conveyor of the monitoring device shown in fig. 3;
FIG. 5 shows a schematic view of the structure of the frame shown in FIG. 4;
FIG. 6 shows an enlarged view of a portion of the frame shown in FIG. 5 at the guide mount;
FIG. 7 is a schematic view of the structure of the adjustable roller frame mounted on the frame of FIG. 5;
Fig. 8 is a schematic view of the idler of fig. 4 in a first contact with the tube strip;
fig. 9 is a schematic view showing the idler of fig. 4 in a second contact with the tube strip;
fig. 10 is a schematic view showing the idler of fig. 4 in a third contact with the tube belt;
fig. 11 shows a flow chart of a monitoring method according to the invention.
Wherein the above figures include the following reference numerals:
1. A roller body; 2, a carrier roller shaft, 3, a bearing, 4, an end cover, 5, a collecting ring, 6, a first connecting wire, 7, a resistance strain gauge, 8, a pipe belt;
9. A carrier roller; 91, a first carrier roller, 92, a second carrier roller, 93, a third carrier roller, 94, a fourth carrier roller, 95, a fifth carrier roller, 96, a sixth carrier roller, 9, carrier rollers, 10 and a frame;
11. the device comprises a first connecting wire, a second connecting wire, a strain regulator, a data acquisition card, a host computer and a data acquisition card, wherein the first connecting wire is connected with the strain regulator;
15. the adjustable carrier roller frame comprises 151, an intermediate supporting plate, 152, a connecting lug, 153, a first fastener threaded hole, 154 and a second fastener through hole;
16. The first fastener is provided with a avoidance hole 17;
18. The device comprises a guide mounting part, 180, a guide mounting space, 181, a first guide mounting piece, 182, a second guide mounting piece, 183, a first plate body, 184, a second plate body, 185 and a first fastener through hole.
Detailed Description
It should be noted that, without conflict, the embodiments of the present application and features of the embodiments may be combined with each other. The application will be described in detail below with reference to the drawings in connection with embodiments.
As shown in fig. 1 to 10, the invention provides a monitoring device, which comprises a tubular belt conveyor, wherein the tubular belt conveyor comprises a frame 10, a pipe belt 8 and a plurality of carrier rollers 9, an avoidance hole 16 is formed in the frame 10, the pipe belt 8 is arranged in the avoidance hole 16 in a penetrating manner, the plurality of carrier rollers 9 are arranged at intervals around the circumference of the pipe belt 8, the carrier rollers 9 comprise carrier roller shafts 2 and carrier roller bodies 1 rotatably sleeved outside the carrier roller shafts 2, a plurality of groups of resistance strain pieces 7 are arranged on the inner wall surfaces of the carrier roller bodies 1 of the plurality of carrier rollers 9 in a one-to-one correspondence manner and are used for monitoring strain effects generated by the corresponding carrier roller bodies 1 in the moving process, and an upper computer 14 is connected with the plurality of groups of resistance strain pieces 7 and is used for receiving monitoring results of the resistance strain pieces 7 of each group and calculating noise of the tubular belt conveyor according to the monitoring results.
The invention adopts the resistance strain gauge 7 to monitor the strain effect of the carrier roller 9, the cost is far lower than that of a non-contact sensor, the resistance strain gauge has better adaptability to parts with lower precision such as the carrier roller 9, the magnitude of the contact force of each carrier roller 9 can be directly obtained by monitoring the strain effect generated by each carrier roller 9 in the moving process, the contact state between the pipe belt 8 and each carrier roller 9 is obtained, the carrier roller 9 with obviously abnormal contact state is found, and the noise judgment rule of the tubular belt conveyor formulated based on the contact state can be used for judging the risk of the moving noise of the pipe belt conveyor, the adjustment of the installation position of the carrier roller 9 is facilitated, and the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the tubular belt conveyor in the noise generating process is solved.
The carrier roller body 1 and the carrier roller shaft 2 of the carrier roller 9 are connected through the bearing 3, and end covers 4 are arranged at the opposite ends of the carrier roller body 1.
As shown in fig. 1, the tubular belt conveyor comprises a strain regulator 12, a data acquisition card 13 and a data acquisition card 13, wherein the strain regulator 12 is connected with the resistance strain gauge 7 and is used for receiving and amplifying a monitoring signal of the resistance strain gauge 7 to generate an amplified signal, and the data acquisition card 13 is connected with the strain regulator 12 and an upper computer 14 and is used for acquiring the amplified signal and transmitting the amplified signal to the upper computer 14.
As shown in fig. 2, the tubular belt conveyor comprises a collecting ring 5, a first connecting wire 6, a second connecting wire 11 and a strain regulator 12, wherein the collecting ring comprises an outer ring and an inner ring, the outer ring is connected with the inner wall surface of a roller body 1, the inner ring is connected with a roller shaft 2, one end of the first connecting wire 6 is connected with the outer ring, the other end of the first connecting wire 6 is connected with a resistance strain gauge 7, one end of the second connecting wire 11 is connected with the inner ring, and the other end of the second connecting wire 11 is connected with the strain regulator 12.
The inner ring and the outer ring of the collecting ring 5 can rotate relatively, signals and currents can be transmitted by sliding contact between elastic pressure of an electric brush and a ring groove of the conducting ring, wherein the outer ring of the collecting ring is matched with the inner wall surface of the carrier roller body 1, the first connecting wire 6 adhered to the inner wall surface of the carrier roller body 1 can be kept relatively static with the carrier roller body 1, even if the resistance strain gauge 7 and the first connecting wire 6 synchronously rotate with the carrier roller body 1 on the premise of being connected with the outer ring of the collecting ring 5, the inner ring of the collecting ring 5 is matched with a carrier roller shaft, the relative static between the second connecting wire 11 and the carrier roller shaft 2 can be guaranteed, and therefore transition of an electric signal from the resistance strain gauge 7 to the strain regulator 12 is achieved.
After the carrier roller 9 is installed, the second connecting wire 11 and the strain conditioner 12 are connected through a quarter bridge, and then the data acquisition card 13 and the upper computer 14 are sequentially connected, so that the monitoring device is built.
As shown in fig. 2, a first wire-releasing groove is formed in the outer circumferential surface of the carrier roller shaft 2, and two ends of the first wire-releasing groove are respectively communicated with the inside and the outside of the carrier roller 9 so as to be used for avoiding the second connecting wire 11.
Specifically, the first wire-laying groove is milled on the outer peripheral surface of the carrier roller shaft 2 without affecting the safety factor of the carrier roller 9, which is beneficial to the extraction of the second connecting wire 11.
As shown in fig. 3, each set of resistive strain gages 7 is adhered to a corresponding carrier roller body 1, and the measured strain amount is wider than that adhered to the carrier roller shaft 2, and is more effective for less accurate components such as the carrier roller 9, and/or each set of resistive strain gages 7 includes a plurality of resistive strain gages 7, the plurality of resistive strain gages 7 being spaced around the axis of the corresponding carrier roller shaft 2 for measuring strain amounts at different circumferential positions of the carrier roller body 1, respectively.
Wherein, each resistance strain gauge 7 is installed at the middle part of the corresponding carrier roller body 1 in the length direction, before assembling the carrier roller 9, the inner surface of the carrier roller body 1 needs to be wiped firstly to remove burrs, lubricating grease and the like, then each resistance strain gauge 7 is stuck on the carrier roller body 1, and finally the carrier roller body 1, the collecting ring 5, the bearing 3, the carrier roller shaft 2 and the end cover 4 are assembled in sequence.
As shown in fig. 4, the avoidance hole 16 is a hexagonal hole, the plurality of carrier rollers 9 include a first carrier roller 91, a second carrier roller 92, a third carrier roller 93, a fourth carrier roller 94, a fifth carrier roller 95 and a sixth carrier roller 96 which are arranged in one-to-one correspondence with six sides of the hexagonal hole, wherein the first carrier roller 91, the second carrier roller 92 and the third carrier roller 93 are positioned below the pipe belt 8, the second carrier roller 92 and the third carrier roller 93 are positioned on two opposite sides of the first carrier roller 91, the fourth carrier roller 94, the fifth carrier roller 95 and the sixth carrier roller 96 are positioned above the pipe belt 8, and the fifth carrier roller 95 and the sixth carrier roller 96 are positioned on two opposite sides of the fourth carrier roller 94.
Specifically, the first, second, and third idlers 91, 92, and 93 play a main supporting role, and the fourth, fifth, and sixth idlers 94, 95, and 96 play a role of maintaining the tubular shape of the tube band 8, and therefore, the monitoring of the strain amounts of the plurality of idlers 9 is mainly performed for the first, second, and third idlers 91, 92, and 93.
In order to ensure the stability of the tube belt 8 of the tubular belt conveyor in the transportation process, the middle section is supported by a plurality of carrier roller groups which are sequentially arranged at intervals along the extending direction of the tube belt 8, and each carrier roller group comprises six carrier rollers 9 which are distributed in a regular hexagon.
As shown in fig. 5 to 8, the tubular belt conveyor includes a plurality of guide mounting portions 18 provided on the frame 10 at intervals around the center line of the escape hole 16, a plurality of adjustable roller frames 15 on which the plurality of carrier rollers 9 are mounted in one-to-one correspondence, and a plurality of adjustable roller frames 15 on which the plurality of guide mounting portions 18 are mounted in one-to-one correspondence and detachably, wherein the positions of the respective carrier rollers 9 with respect to the tubular belt 8 are adjusted by adjusting the positions of the respective adjustable roller frames 15 on the respective guide mounting portions 18. Like this, through setting up adjustable carrier roller frame 15 and direction installation department 18, can realize the quick adjustment to the mounted position of bearing roller 9 to guarantee the contact state between tube band 8 and each bearing roller 9, reduced economic cost greatly, improved work efficiency.
Specifically, the adjustable carrier roller frame 15 includes a center support plate 151 and two connection lugs 152 provided near opposite ends of the center support plate 151, respectively, the guide mounting portion 18 includes a guide mounting space 180 extending in a radial direction of the tube strip 8, the center support plate 151 is adjustably provided in the guide mounting space 180 in a direction toward or away from the tube strip 8 and detachably connected with the guide mounting portion 18, and the two connection lugs 152 extend toward a direction away from the frame 10 to be connected with opposite ends of the carrier roller 9, respectively.
As shown in fig. 5, the guide mounting portion 18 includes a first guide mounting member 181 and a second guide mounting member 182 that are disposed opposite to each other and spaced apart from each other, and each of the first guide mounting member 181 and the second guide mounting member 182 includes a first plate 183 and a second plate 184 that are connected to each other, the first plate 183 being perpendicular to the main plate of the rack 10, and the second plate 184 being parallel to the main plate of the rack 10 and being located at a side of the first plate 183 remote from the main plate of the rack 10 so as to together define the guide mounting space 180.
As shown in fig. 4, opposite ends of the intermediate support plate 151 are connected to the first plate bodies 183 of the first and second guide mounting members 181 and 182 through first fastening members 17, first fastening member through holes 185 are provided in each of the first plate bodies 183, first fastening member screw holes 153 are provided in opposite ends of the intermediate support plate 151, and the first fastening members 17 are screw-connected to the first fastening member screw holes 153 after passing through the first fastening member through holes 185.
Specifically, the first fastening member 17 is a set screw capable of locking the respective adjustable roller frame 15 to the guide mounting portion 18 while positioning the adjustable roller frame 15, so as to secure the supporting rigidity of the respective carrier roller 9.
As shown in fig. 4, the opposite ends of the carrier roller shaft 2 are connected with the two connecting lugs 152 through second fasteners, the opposite ends of the carrier roller shaft 2 are respectively provided with second fastener threaded holes, the two connecting lugs 152 are respectively provided with second fastener through holes 154, and the second fasteners penetrate through the second fastener through holes 154 and are in threaded connection with the second fastener threaded holes.
The invention further provides a monitoring method suitable for the monitoring device, the monitoring method comprises the steps of making a noise judging rule, controlling the tubular belt conveyor to move, observing a test contact state between the tubular belt conveyor 8 and each carrier roller 9, collecting test strain amounts of the corresponding carrier rollers 9 monitored by each group of resistance strain pieces 7, performing data processing on the test strain amounts to obtain test stress of the corresponding carrier rollers 9, performing simulation analysis on the tubular belt conveyor based on the test contact state between the tubular belt 8 and each carrier roller 9 and the test stress of each carrier roller 9 to obtain overall noise of the tubular belt conveyor, obtaining a preset noise range and a preset stress range of each carrier roller 9 corresponding to the preset noise range according to noise environmental protection standards, monitoring working conditions in real time, controlling the tubular belt conveyor to work normally, observing real-time contact states between the tubular belt conveyor 8 and each carrier roller 9, collecting real-time strain amounts of the corresponding carrier rollers 9 monitored by each group of resistance strain pieces 7, performing data processing on the real-time strain amounts to obtain real-time stress of the corresponding carrier rollers 9, and comparing the real-time stress of each carrier roller 9 with the preset noise range to judge whether the overall noise of the tubular belt conveyor is in the preset overall noise range.
Specifically, the monitoring method of the invention comprises the following steps:
step S1, formulating a noise judgment rule:
s11, controlling the tubular belt conveyor to move;
step S12, observing the test contact state between the pipe belt 8 and each carrier roller 9;
Step S13, collecting the test strain quantity of the corresponding carrier roller 9 monitored by each group of resistance strain gauges 7 and carrying out data processing on the test strain quantity to obtain the test stress of the corresponding carrier roller 9;
Step S14, performing simulation analysis on the tubular belt conveyor based on the test contact state between the pipe belt 8 and each carrier roller 9 and the test stress of each carrier roller 9 to obtain the overall noise of the tubular belt conveyor;
Step S15, obtaining a preset noise range and a preset stress range of each carrier roller 9 corresponding to the preset noise range according to the noise environmental protection standard;
step S2, monitoring working conditions in real time:
s21, controlling the tubular belt conveyor to work normally;
Step S23, observing the real-time contact state between the pipe belt 8 and each carrier roller 9;
step S23, collecting the real-time strain quantity of the corresponding carrier roller 9 monitored by each group of resistance strain gauges 7 and carrying out data processing on the real-time strain quantity to obtain the real-time stress of the corresponding carrier roller 9;
And S24, comparing the real-time stress of each carrier roller 9 with a preset stress range to judge whether the real-time integral noise of the tubular belt conveyor is in the preset noise range.
Real-time contact states between the tube belt 8 and the carrier rollers 9 can be obtained based on real-time monitoring of the strain of the carrier rollers 9 of the tube belt conveyor in the moving process, but the overall accuracy of the tube belt conveyor is low, the installation conditions of the carrier rollers 9 are inconsistent, and the real-time transport amount in the tube belt 8 is not constant, so that the real-time strain of the carrier rollers 9 is influenced. Merely comparing the monitored real-time strain amount of each carrier roller 9 with the strain amount of the carrier roller 9 under normal conditions is not accurate enough as a basis for judging whether the contact state of each carrier roller 9 is abnormal, which is easy to judge for a carrier roller 9 which is not contacted at all, but difficult to judge for a carrier roller 9 which is not abnormal in contact state significantly, so that an effective judgment criterion cannot be formed. Therefore, the invention provides a monitoring method for judging the overall noise of the tubular belt conveyor during movement and giving early warning to risks in the early stage based on monitoring the strain amount of each carrier roller 9.
The monitoring method of the invention utilizes a certain sampling frequency to collect the strain quantity of each carrier roller 9, and carries out data processing according to the method to obtain the stress condition of the corresponding carrier roller 9 so as to carry out stress monitoring on the whole carrier roller group of the tubular belt conveyor, thereby judging the contact state of each carrier roller 9.
The contact state of each carrier roller 9 of the tubular belt conveyor in the transportation process is obtained through the monitoring device, and then the overall noise of the tubular belt conveyor under different contact working conditions is obtained based on a simulation method, so that a noise judgment rule taking the contact state of each carrier roller 9 as a judgment basis is formulated, and the risk judgment of the overall noise of the tubular belt conveyor in the transportation process is carried out.
In the transportation process of the tubular belt conveyor, firstly, according to the observed real-time contact state of each carrier roller 9, the carrier roller 9 with obviously abnormal contact state is found out and traced, and then, based on a noise judgment rule, the real-time contact state of each carrier roller 9 is comprehensively judged according to the monitored real-time strain quantity and the calculated real-time stress of each carrier roller 9. The effect can also reduce the misjudgment rate of the carrier roller faults and improve the working efficiency while ensuring that the overall noise of the tubular belt conveyor is within the noise environmental protection standard.
In the monitoring method of the present invention, the calculation formula of the stress of the carrier roller 9 includes: Wherein, U is the voltage value measured by the resistance strain gauge 7, U1 is the reference zero-drift voltage, K is the sensitivity coefficient of the resistance strain gauge 7, U0 is the bridge voltage of the bridge between the second connecting wire 11 connected with the resistance strain gauge 7 and the strain regulator 12, n is the bridge arm number of the bridge, KS is the gain coefficient of the strain regulator 12, and E is the elastic modulus of the roller body 1.
In the transportation process of the tubular belt conveyor, the pipe belt 8 acts on the surface of the carrier roller 9, the carrier roller 9 carries the pipe belt 8 to move, the resistance strain gauge 7 stuck on the inner wall surface of the carrier roller body 1 generates a strain signal along with the deformation of the carrier roller body 1, the strain signal is transmitted to the collecting ring 5 through the first connecting wire 6, and the strain signal is further transmitted to the strain regulator 12 through the collecting ring 5, so that the measurement of the strain quantity of each carrier roller 9 of the tubular belt conveyor in the movement process is realized.
The above calculation formula can be obtained by the following steps:
(1) The micro strain mu epsilon of the carrier roller 9 can be obtained according to the performance parameters of the resistance strain gauge and the following formula 1.
(2) The stress σ of the carrier roller 9 can be obtained from the elastic modulus E of the carrier roller body 1 and the following equation 2.
Sigma=e×epsilon 2
The monitoring method comprises the steps of controlling a working state signal lamp of the tubular belt conveyor to display green when the contact state between the tubular belt 8 and each carrier roller 9 is not obviously abnormal and the real-time overall noise of the tubular belt conveyor is within a preset noise range, controlling the working state signal lamp of the tubular belt conveyor to display yellow when the contact state between the tubular belt 8 and each carrier roller 9 is obviously abnormal and the real-time overall noise of the tubular belt conveyor is within the preset noise range, and controlling the working state signal lamp of the tubular belt conveyor to display red when the real-time overall noise of the tubular belt conveyor exceeds the preset noise range.
The monitoring method of the invention comprises the following steps:
(1) The contact state of the tube belt 8 with the carrier rollers 9 of each carrier roller group is analyzed, and the three working conditions comprise single carrier roller contact as shown in fig. 8, two carrier roller contacts as shown in fig. 9 and three carrier roller contacts as shown in fig. 10.
(2) And (3) carrying out simulation analysis on the overall noise of the tubular belt conveyor under each contact working condition to obtain the overall noise of the tubular belt conveyor under each contact working condition, obtaining a preset noise range and a preset stress range of each carrier roller 9 corresponding to the preset noise range according to noise environmental protection standards, so as to formulate a contact criterion and a contact threshold standard of each carrier roller group, and taking the contact criterion and the contact threshold standard as a judgment basis of the overall noise of the tubular belt conveyor in the transportation process.
(3) To ensure traceability during monitoring, each set of idlers is first numbered, N-M being the number of the set, n=1, 2, 3, 4, M being the number of the idler 9 below the tube band 8 in the respective set, e.g. m=1 being the first idler 91 directly below the tube band 8, m=2 and 3 being the second and third idlers 92 and 93 on the left and right sides of the first idler 91, respectively.
(4) When the tubular belt conveyor works normally, the contact state of each carrier roller is counted according to the stress monitoring value, and the carrier roller 9 with obvious abnormal contact state is traced.
(5) Under the condition that the contact state of the carrier roller 9 is obviously abnormal, pre-warning the noise risk of the tubular belt conveyor according to the counted real-time contact state of the carrier roller group and the noise judging rule, tracing the noise abnormal position if the real-time overall noise is judged not to be in the preset noise range, and formulating an optimal adjustment strategy of the contact state of the carrier roller group at the noise abnormal position to guide a worker to adjust or replace the corresponding carrier roller 9 in time, so that the position of the carrier roller group with no obvious abnormality of the contact state but the overall noise not to be in the preset noise range is adjusted, and the noise environment-friendly standard is met.
(6) The working state signal lamps of the tubular belt conveyor are classified into three types, namely green, yellow and red, based on the contact state of the tube belt 8 and each carrier roller 9 and the overall noise of the tubular belt conveyor.
From the above description, it can be seen that the above embodiments of the present invention achieve the following technical effects:
The monitoring device comprises a tubular belt conveyor, wherein the tubular belt conveyor comprises a frame 10, a pipe belt 8 and a plurality of carrier rollers 9, an avoidance hole 16 is formed in the frame 10, the pipe belt 8 is arranged in the avoidance hole 16 in a penetrating mode, the plurality of carrier rollers 9 are arranged at intervals around the circumference of the pipe belt 8, the carrier rollers 9 comprise carrier roller shafts 2 and carrier roller bodies 1 rotatably sleeved outside the carrier roller shafts 2, a plurality of groups of resistance strain pieces 7 are arranged on the inner wall surfaces of the carrier roller bodies 1 of the plurality of carrier rollers 9 in a one-to-one correspondence mode and used for monitoring strain effects generated by the corresponding carrier roller bodies 1 in the moving process, and an upper computer 14 is connected with the plurality of groups of resistance strain pieces 7 and used for receiving monitoring results of the resistance strain pieces 7 of each group and calculating noise of the tubular belt conveyor according to the monitoring results. In this way, the invention adopts the resistance strain gauge 7 to monitor the strain effect of the carrier roller 9, the cost is far lower than that of a non-contact sensor, the invention has better adaptability to the components with lower precision such as the carrier roller 9, the magnitude of the contact force of each carrier roller 9 can be directly obtained by monitoring the strain effect generated by each carrier roller 9 in the moving process, the contact state between the pipe belt 8 and each carrier roller 9 is obtained, the carrier roller 9 with obvious abnormal contact state is found, and the noise early warning criterion of the tubular belt conveyor formulated based on the contact state can be used for judging the risk of the moving noise of the tubular belt conveyor, thereby being beneficial to the adjustment of the installation position of the carrier roller 9 and solving the problem that the force monitoring method in the prior art is not suitable for monitoring the force of the tubular belt conveyor in the noise generating process.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
The relative arrangement of the components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present application unless it is specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective parts shown in the drawings are not drawn in actual scale for convenience of description. Techniques, methods, and apparatus known to one of ordinary skill in the relevant art may not be discussed in detail, but should be considered part of the specification where appropriate. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that like reference numerals and letters refer to like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
In the description of the present application, it should be understood that the azimuth or positional relationships indicated by the azimuth terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal", and "top, bottom", etc., are generally based on the azimuth or positional relationships shown in the drawings, and are merely for convenience of describing the present application and simplifying the description, and these azimuth terms do not indicate and imply that the apparatus or elements referred to must have a specific azimuth or be constructed and operated in a specific azimuth, and thus should not be construed as limiting the scope of the present application, and the azimuth terms "inside and outside" refer to inside and outside with respect to the outline of each component itself.
Spatially relative terms, such as "above," "upper" and "upper surface," "above" and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "above" or "over" other devices or structures would then be oriented "below" or "beneath" the other devices or structures. Thus, the process is carried out, the exemplary term "above" may be included. Upper and lower. Two orientations below. The device may also be positioned in other different ways (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
In addition, the terms "first", "second", etc. are used to define the components, and are only for convenience of distinguishing the corresponding components, and the terms have no special meaning unless otherwise stated, and therefore should not be construed as limiting the scope of the present application.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.