The Design And Engineering Accomplishment Of Sprocket’s Failure Automatic Detecting System

For the modern cement production line, key equipments specially those large rotating equipments runs continuously and normally is the guarantee of reliable production. Therefore it comes with more strict requirements for the automatic detecting of these equipments’ failure. Inclined slide fastener machine is a kind of cable-stayed lifting equipment, and it is widely used in production lines of cement, chemical industry and stone. Sprocket, as the most significant component of inclined slide fastener machine, is prone to failures of deformation and stuck owning to enormous number, harsh working environment, and machine aging. Currently the production lines are commonly detected by manual work with difficulties for comprehensive inspection, and that is easily leads to a failure of sprocket’s drag or drop, which will bring about a negative impact on production. Accordingly it’s necessary to design an automatic detecting system for sprocket’s failure based on the analysis of the structure and working of sprockets, and combined with the actual situations. The system is capable of detecting the sprockets in real time, and guaranteeing the sprocket’s reliable working.This thesis elaborates the components of automatic failure detection system for sprockets based on the detection principles, and offers the solution of both hardware and software design. The system adopts technologies of Hall sensor, RFID, and ultrasonic to detect the sprockets in real time including data acquisition, data processing and design of host computer. According to the analysis of system requirements, the data acquisition part detects the sprocket’s status. The data processing part enquiries, processes, determines, and displays the sprocket’s information on the LCD. The network communication module transmits data to host computer and the system will send alarming short message to attendants instantly when failure occurs. The host computer stores the received sprocket’s information in database and supplies the query, management, and analysis functions of sprocket’s information in client application.Main work of this thesis consists of hardware and software design. The hardware part contains MCU, module selection in extension circuit, schematic diagram design, PCB design, proofing, welding and debugging, and chassis design. The software part contains the program design of data acquisition, data processing, and device drivers in each module, and the communication protocol making. The data processing program running in host computer is written with VC6.0, the application program running in host computer is written with VS2010, and the sprocket’s information is managed by MySQL database. This thesis tests the functions after system building.This thesis studies and accomplishes a sprocket’s failure automatic detecting system to substitute for manual work, which will improve detection efficiency, and that is of practical application value.