3136 螺旋输送机设计1
3136 螺旋输送机设计1,螺旋,输送,设计
1带式输送机保护系统的研究带式输送机作为一种连续运输机械,被广泛应用在煤炭、冶金粮食等领域。但是,带式输送机的故障一直困扰着其安全、可靠的运行.特别在矿井生产中,一旦发生故障,其将直接影响矿井生产,甚至造成人身伤亡。因此,确保带式输送机安全、可靠的运行,对矿井的生产安全具有重要意义。本文选用钢绳芯带式输送机作为研究对象,通过分析其存在的故障,从三个方面对其进行研究,即接头断裂及张力超限、纵向撕带、带式输送机火灾。通过对其发生的故障进行分析,探究故障发生的机理,然后选用可行的监测方法对其进行监测和预防。本文采用嵌入式系统来设计带式输送机保护系统,选用基AR核心的S3C2410 作为保护系统的控制中心,选用嵌入式 Linux 作为系统的软件开发平台。在硬件设计方面,根据系统需要围绕 S3C2410 来构建硬件平台。对于软件部分,详细介绍了一般驱动程序的设计方法和步骤,并根据硬件及嵌入式Linux系统需要,完成了 CAN 总线、LCD、A/D 等驱动程序设计。最后,针对论文设计的硬件和驱动程序,进行了应用程序的开发和程序的调试带式输送机是现代散状物料连续运输的主要设备,被广泛应用在煤炭、冶金、电力、化工、矿山、港口、建材、粮食等领域,在国民经济中发挥着重要作用。然而,带式输送机作为一种连续运输机械,特别在矿井生产中,一旦发生故障,将直接影响生产,甚至造成人身伤亡。因此,确保其安全,可靠地运转对矿2井的安全生产具有重要意义。对于矿用钢绳芯带式输送机来说,其单机工作长度较长,除要解决一般带式输送机共有的滚筒打滑、胶带跑偏、托辊寿命低等问题外,有效地预防和避免接头断裂、纵向撕带、胶带机火灾等重大事故发生显得十分重要。对于跑偏和滚筒打滑等故障的监测技术已十分成熟,并已获得广泛应用。而对于断带、撕带、火灾等重大事故的实时监测问题却一直没有得到很好的解决,先后出现了不少监测方法和技术,但都存在着不同程度的问题。本文将着重介绍目前国内外曾出现的。针对钢绳芯带式输送机断带、撕带、火灾等重大事故的各类监测方法和技术,然后提出一种实时监测与保护系统,并且完成相应的硬件和驱动程序设计。历经近两个世纪的发展,带式输送机的技术已经发生了翻天覆地的变化。从采用天然材料的输送带到如今采用高强度人造合成材料,从短距离,低速到现在的长距离、高速,在新技术的推动下,带式输送机的性能正在不断地提高。对于带式输送机的技术来说,国外一直处于领先水平,主要体现在以下两个方面:一方面,在本身的技术和装备方面有了巨大的发展,如大运量、高运速、长距离等大型带式输送机已成为其主要的研究和发展方向;另一方面,带式输送机的多元化、应用范围的扩大化也取得了长足的发展,如大倾角带式输送机机、平面或空间转弯带式输送机、管状带式输送机等各种机型。另外,国外带式输送机采用了大量的最新技术,如:动态分析技术、可控启动技术、自动张紧技术、多点驱动技术、机尾快速自移技术、电控与监测自动化技术将直接影响生产,甚至造成人身伤亡。因3此,确保其安全可靠地运转对矿井的安生产具有重要意义。对于矿用钢绳芯带式输送机来说,其单机工作长度较长,除了要解决一般带式输送机共有的滚筒打滑、胶带跑偏、托辊寿命低等问题外,有效地预防和避免接头断裂、纵向撕带、胶带机火灾等重大事故发生显得十分重要。对于跑偏和滚筒打滑等故障的监测技术已十分成熟,并已获得广泛应用。而对于断带、撕带、火灾等重大事故的实时监测问题却一直没有得到很好的解决,先后出现了不少监测法和技术,但都存在着不同程度的问题。本文将着重介绍目前国内外曾出现的针对钢绳芯带式输送机断带、撕带、火灾等重大事故的各类监测方法和技术,然后提出一种实时监测与保护系统,并且完成相应的硬件和驱动程序设计。历经近两个世纪的发展,带式输送机的技术已经发生了翻天覆地的变化。从采用天然材料的输送带到如今采用高强度人造合成材料,从短距离,低速到现在的长距离、高速,在新技术的推动下,带式输送机的性能正在不断地提高。对于带式输送机的技术来说,国外一直处于领先水平,主要体现在以下两个方面:一方面,在本身的技术和装备方面有了巨大的发展,如大运量、高运速、长距离等大型带式输送机已成为其主要的研究和发展方向;另一方面,带式输送机的多元化、应用范围的扩大化也取得了长足的发展,如大倾角带式输送机机、平面或空间转弯带式输送机、管状带式输送机等各种机型。另外,国外带式输送机采用了大量的最新技术,如:动态分析技术、可控启动技术、自动张紧技术、多点驱动技术、机尾快速自移技术、电控与监测自动化技术等。这些新技术的采用使带式输送机的设计、运行效率、可靠性都有了极大的提高,其代表了当今带式输4送机发展的最新方向。经过多年的发展,我国带式输送机的发展也有长足的发展,技术水平有了很大的提高,特别是煤矿井下使用的大功率、长距离带式输送机,其关键技术的研究和新产品的开发都取得了很大的进步。如大倾角长距离带式输送机成套设备,高产高效工作面顺槽可伸缩带式输送机等均填补了国内外空白,并对带式输送机的关键技术及其主要元部件进行了理论研究和产品开发,研制成功了多种软启动和制动装置以及以 PLC 为核心的可编程电控装置,驱动系统采用调速液力耦合器和行星齿轮减速器等。与国外技术相比,我国带式输送机技术还有很大的差距,主要表现在:(1)大型带式输送机关键核心技术上的差距带式输送机动态分析与监测技术长距离、大功率带式输送机的关键技术是动态分析和监测,它是制约大型带式输送机发展的核心技术。可靠的可控软启动技术与功率均衡技术长距离大运量带式输送机由于功率大、距离长且为多电机驱动,必须采用软启动方式来降低输送机的张力,特别是采用多电机驱动时。目前可控软启动装置大多使用国外的产品,这使产品的成本大大增加,急需国产化。11111111(2)技术性能上的差距我国带式输送机的主要性能与参数已不能满足高产高效矿井的需要,尤其是顺槽可伸缩带式输送机的关键元部件及其功能,如自移机尾、高效储带与张紧装置等都与国外有很大差距。(3)可靠性、寿命上的差距主要体现在以下几个方面:输送带抗拉强度、输送带接头强5度、托辊寿命、输送机减速寿命,带式输送机上下可运行时可靠性差距。(4)控制系统上的差距差距主要存在于驱动方式、监控装置、输送机保护装置三个方面。带式输送机保护系统发展现状带式输送机在运行过程中,由于其工作环境恶劣,连续性工作时间长,总会出现一些故障。常见的故障主要有:(1)输送带跑偏(2)带式输送机的撒料(3)异常噪音(4)驱动减速机短轴(5)输送带打滑(6)输送带寿命短(7)带式输送机凸弧段及凹弧段曲率半径对输送带机托辊的影响(8)托管运转不灵活(9)托辊损坏(10)机头堆煤(11)输送机火灾针对上述故障,需要专门的保护系统来预防和监测故障的发生,从而使带式输送机能够安全平稳的运行。对于上述的大部分故障,我国已经开发出相应的产品来对带式输送机进行保护。如由兖州科欣机电设备制造有限公司生产的带式输送机综合保护装6置,可实现带式输送机打滑、超温、洒水、堆煤、急停、跑偏、撕裂、烟雾等基本保护。用先进的以太网及现场总线技术,不但可以实现对带式输送机打滑(超速)、跑偏、断带、堆煤(堵塞)、满仓、超温、洒水、烟雾等多项保护外,还可以显示带式运输机的运行状态、生产工况参数、设备故障状态等。但是,对于影响输送带寿命的接头断裂及张力超限、纵向撕裂和输送带火灾这三类故障,尚未出现较为可靠的方法和技术来对其进行实时监控。虽然先后出现了不少监测方法和技术,但都存在着不同程度的问题。因此,开发研制带式输送机实时工况监测与综合保护系统,以便及时有效地预防和避免各类事故的发生是十分必要的 .。本文研究开发钢绳芯带式输送机实时监测与保护系统,主要是基于 ARM9处理器 S3C2410 与嵌入式 Linux 的中央控制平台。系统通过获取带式输送机的各类传感器的数据,进行分析和比较然后得出对带式输送机故障的诊断和预报。 7Belt conveyor as a Belt conveyor protection systems continuous transport machinery, is widely used in coal Metallurgical grain and other fields.But the failure of the belt conveyor has been plagued by its safe and reliable operation.Mine production in particular, in the event of failure, it will directly affect mine production, and even cause personal injury or death. Therefore, to ensure that the belt conveyor safety, reliable operation, the mine production safety significance. This article selected steel cord belt conveyor as the object of study, by analyzing the failure of its existence, from the three aspects of their research, Joints and tension gauge, longitudinal tear belt, belt conveyor fire. By its failure to analyze, explore the mechanism of failure, then the selection of feasible monitoring methods, monitoring and prevention.But the failure of the belt conveyor has been plagued by its safe and reliable operation.Mine production in particular, in the event of failure, it will directly affect mine production, and even cause personal injury or death. Therefore, to ensure that the belt conveyor safety, reliable operation, the mine production safety significance. This article selected steel cord belt conveyor as the object of study, by analyzing the failure of its existence, from the three aspects of their research, Joints and tension 8gauge, longitudinal tear belt, belt conveyor fire. By its failure to analyze, explore the mechanism of failure, then the selection of feasible monitoring methods, monitoring and prevention.Finally, the paper design of hardware and drivers, application development and debuggingThe belt conveyor is a modern bulk materials for transport equipment, are widely used in coal, metallurgy, electric power, chemical, mining, ports, building materials, food and other fields in the national economy plays an important role 1. However, the transport machinery as a continuous belt conveyor, especially in mine production, in the event of failure, will directly affect production, and even cause personal injury or death. Therefore, to ensure their safety, reliable operation of the mine production safety significance.For mining the steel cord belt conveyor, the length of its stand-alone work longer to solve the belt conveyor Total rollers skid, belt run, low roller life problems, to effectively prevent and avoidjoints, longitudinal tear tape, the tape machine fire, and other major incidents is very important. Deviation, and roller slip fault monitoring technology has been very mature, and has been widely used. Belt, real-time monitoring of the tear tape, fires and other major incidents has not been satisfactorily resolved, has appeared in a number of monitoring methods and techniques, but there are varying degrees of problems. The article will focus on at home and abroad had appeared.9Steel Cord Belt Conveyor belt, tear tape, fires and other accidents of various types of monitoring methods and techniques, and then proposed a real-time monitoring and protection system, and complete the appropriate hardware and driver design. After nearly two centuries of development, the belt conveyor technology has undergone enormous changes. Now using high-strength man-made synthetic material from the conveyor belt using natural materials, from a short distance, low speed to the long-distance, high speed, driven by new technology, the performance of the belt conveyor is continuously improvingBelt conveyor technology abroad has been at the leading level, mainly in the following two aspects: on the one hand, the tremendous development in technology and equipment, such as large capacity, high transport speed, longlarge distance belt conveyor has become its main direction of research and development; the other hand, the diversification of the belt conveyor, the expansion of the scope of application has also made considerable development, such as angle belt conveyor machine.plane or space to turn belt conveyors, tubular belt conveyor models. In addition, foreign belt conveyor using the latest technology, such as: dynamic analysis techniques, controlled start technology, automatic tensioners technology, multi-drive technology, the tail quickly self-shifting technology, electronic control and monitoring automation technology will be 10directly impact on production, and even cause personal injury or death. Therefore, to ensure safe and reliable operation of great significance to the mine safety and production.For mining the steel cord belt conveyor, the length of its stand-alone work longer, in addition to common roller skid to solve the general belt conveyor belt run, low roller life problems, to effectively prevent and avoidjoints, longitudinal tear tape, the tape machine fire, and other major incidents is very important. Deviation, and roller slip fault monitoring technology has been very mature, and has been widely used. Belt, real-time monitoring of the tear tape, fires and other major incidents, but has not been satisfactorily resolved, has appeared in a number of monitoring methods and techniques, but there are varying degrees of problems. This article will focus on the present appear for steel cord belt conveyor belt, tear tape, fires and other major incidents of various types of monitoring methods and techniques, and then proposed a real-time monitoring and protection systems, and complete the hardware and driver design. After nearly two centuries of development, the belt conveyor technology has undergone enormous changes. Now using high-strength man-made synthetic material from the conveyor belt using natural materials, from a short distance, low speed to the long-distance, high speed, driven by new technology, the performance of the belt conveyor is continuously improving.11Belt conveyor technology abroad has been at the leading level, mainly in the following two aspects: on the one hand, the tremendous development in technology and equipment, such as large capacity, high transport speed, longlarge distance belt conveyor has become its main direction of research and development; the other hand, the diversification of the belt conveyor, the expansion of the scope of application has also made considerable development, such as angle belt conveyor machine.plane or space to turn belt conveyors, tubular belt conveyor models.In addition, foreign belt conveyor using the latest technology, such as: dynamic analysis techniques, controlled start technology, automatic tensioners technology, multi-drive technology, the tail quickly self-moving technology, electronic control and monitoring automation technology. Adoption of these new technologies to the design of the belt conveyor, operating efficiency, reliability has improved greatly, which represents the latest direction of todays belt conveyor. After years of development, the development of our belt conveyors also have made great progress, the technical level has been greatly improved, especially the coal mine to use the high-power, long distance belt conveyor, and its key technologies and new products development have made great progress. Such as the big dip long distance belt conveyor equipment, high yield and efficient working face telescopic belt conveyor, etc. to fill gaps in the domestic and foreign, and belt 12conveyor technology and its main components, a theoretical study and product development, successfully developed a variety of soft start and braking device and the PLC as the core programmable electronic control device, the drive system with variable speed hydraulic coupling and planetary gear reducer.Compared with foreign technology, the belt conveyor technology in China still lags behind, mainly: (1) large belt conveyor key core technological gap(1) belt conveyor dynamic analysis and monitoring long-distance, high-power belt conveyor technology is the dynamic analysis and monitoring, which is the core technology to restrict the development of large belt conveyor controlled soft-start technology and the power balance long distance and large capacity belt conveyor power, long distance, reliable and multi-motor drive, you must use a soft start to reduce the tension of the conveyor, in particular the multi-motordrive. Controlled soft-start devices mostly use foreign products, which makes the cost of the product greatly increased the urgent need of localization.(2) technical performance gapThe belt conveyor performance and parameters of our country can no longer meet the needs of the high yield and efficient mine, especially the smooth groove telescopic belt conveyor key components and their functions, such as shift of the tail, efficient storage with tensioning deviceand so have a 13big gap with foreign.(3) reliability, the gap in life expectancyIs mainly reflected in the following areas: tensile strength of the conveyor belt, conveyor belt joint strength, roller life, reliability gap between the conveyor reducer life, can run up and down the belt conveyor.(4) the gap on the control systemThe gap is mainly for driving, monitoring devices, conveying the three aspects of the machine protection device.Belt Conveyor Protection System Development StatusThe belt conveyor during operation, due to their poor working conditions, the continuity of long working hours, there will always be some failures. Common fault:(1) conveyor belt deviation(2) Scatter material of the belt conveyor(3) abnormal noise(4) driver reducer short axis(5) conveyor belt slipping(6) conveyor short life.(7) belt conveyor convex arcs and concave radius of curvature of the roller of the conveyor belt machine(8) managed operation is not flexible(9) roller damage(10) head the pile of coal(11) conveyor fire14In response to these failures, the need of special protection systems to prevent the occurrence and monitoring failure, so that the belt conveyor can secure and running smoothly. For the majority of these failures, China has developed the appropriate product to protect belt conveyors. Limited production belt conveyor protection devices, such as by Yanzhou Kexin mechanical and electrical equipment manufacturing can achieve belt conveyor skid, over-temperature, watering the pile of coal, emergency stop, the deviation, tearing, smoke protection. With advanced Ethernet and fieldbus technology, not only can slip on the belt conveyor (speeding), deviation off with coal heap (blocked), a number of protection outside warehouse full of over-temperature, sprinklers, smoke, can also display the operational status of the belt conveyor, the parameters of the production conditions, equipment failure status. Joints and tension of the conveyor belt life gauge, longitudinal tear and conveyor belt fires these three types of failure, however, has not yet appeared more reliable methods and techniques to their real-time monitoring. Has appeared in a number of monitoring methods and techniques, but there are problems of varying degrees. Therefore, the development of the belt conveyor real-time condition monitoring and protection system, in order to timely and effective manner to prevent and avoid the occurrence of accidents is very necessary.15In this paper, the development of real-time monitoring and protection of steel cord belt conveyor system, central control ARM9 S3C2410 processor with embedded Linux-based platform. System by getting the belt conveyors of various types of sensor data for analysis and comparison and then come to the diagnosis and prediction of the belt conveyor failure.Design and Research In this paper, the following aspects:(1) analysis of the three types of failure of the steel core rope belt conveyor (Joints and longitudinal tear, fire, tension gauge, etc.) occurs because the design of the sensor selection and signal conversion circuit;(2) for the actual needs of the belt conveyor protection systems, custom platform plates, complete chip selection, system selection;(3) software requirements for belt conveyor protection systems, the completion of each module, including the design of the CAN, LCD, A / D, keyboard and other drivers;(4) (4) build a program development environment, driver and application debugging. Belt conveyor failure analysis and monitoring methodsThe belt conveyor failures are mainly distributed in three aspects: Joints and tension gauge monitoring, longitudinal tear with monitoring and transport machine-fire monitoring. 16Thesis from the three aspects of the belt conveyor failures were analyzed to determine the monitoring methods and sensors to choose. Monitoring of belt conveyor Joints(1) connector fractureTape belt conveyor parts, it is carrying, but also a force transmission. Belt conveyor operation of the process, the tape to withstand a variety of different nature and size of loads, it is extremely complex stress state, this state makes the overall characteristics of the belt conveyor impact is very large. At the same time, the cost of tape about half the cost of the entire belt conveyor, plays an important role in the economy. Tape structure can be divided into the Steel Belt and fabric cord belt. The fabric cord belt type of the vinylon core, ordinary canvas core, nylon core, from top to bottom cover and with a core composition. With a core made by the warp and weft knitting fabric layer, whose role is to pass traction, load carrying and loading and unloading of materials on the impact of the tape.Structurally, it is a composite material. Steel Belt with core layout consists of a series of parallel, together with a core adhesive rope, is typical of orthotropic materials, the longitudinal force to bear by the rope. Which is characterized by high strength, the longitudinal elastic modulus, good impact resistance. However, relative to the fabric cord belt, its viscous characteristics than the fabric cord belt is weak 3. 17Causing the conveyor belt joint damage and fracture are many reasons, incorrect coating for example, due to the production process, coated with liquid adhesive, wrong to suppress temperature, and load imbalance and belt deviation 6. However, no matter what causes joint damage and even rupture, are inevitably accompanied by the connection zone of deformation increases and the steel core tic Often the past, the tensile deformation of the connector region growing, and finally, when deformation increases to a limit, it not enough to withstand the work load will result in the connection zone deformation increases rapidly, resulting in the belt.The introduction of the conveyor belt inherent characteristic curve FL (tension - length) curve, we can further instructions.Allow for the most with the deformation. Inherent characteristic curve of the conveyor belt (FL curve) changes with the change of strain and tension. When the strain and tension increase, the curve moves to the right along the L axis. Become weak due to joint stiffness and strength will also lead to the curve slope decreases. If the damage of the joints continue to develop, the amount of drift of the FL curve and slope reduction is also increasing (2) the selection of the sensor system uses Hall sensors to monitor the deformation of the connector area. Hall sensor consists of two parts: the Hall element and magnetic blocks, according to the Hall effect principle, through the Hall element to feel the magnets 18cause the magnetic field changes. Hall sensor uses a Hall element for the monostable switch integrated Hall element, the repeatability of positioning and high precision, fast response frequency (up to 50kHz), is an ideal location of the monitoring sensors.(2) connector, the length of the measurement methodThe so-called joint deformation, in fact, joints deformed and deformed joints regional difference. Can be monitored by monitoring the deformation of the joint changes in the length of the connector region. Hall element to measure the connector length There are many ways, their common characteristics depend on the magnetic field positioning components, and to feel the position of the magnet through the Hall element, thus the connector length. The system uses the principle of the test shown in Figure 2-3, the magnets 1,2 embedded in the region of belt joints at both ends, is installed in a fixed position of the belt below the two Hall elements a, b, of which, a should keep the proper distance between a and b, and the rest of the belt should also maintain the right distance. When the belt speed v through the Hall element, due to the Hall effect, the Hall element four pulse signal. Shown in Figure 2-4, set up in which four pulse interval t1, t2, t3; practical work belt usual
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