Development Of Online Monitoring And Early Warning System For Rocker Operation Safety

According to the common fault characteristics of shearer rocker,this paper designs a safety on-line monitoring and early warning system for the rocker operation of the shearer with STC as the master chip.The system mainly realizes the data acquisition,data transmission,data storage,data display and safety warning of the temperature and vibration parameters of the key components of the shearer's rocker in operation through the multi-channel signal acquisition technology and bus communication technology.The system mainly consists of STC single-chip hardware test system,the next bit machine software programming and industrial computer management of three parts.The whole test system includes:master chip,multi-channel data acquisition module,data storage module,analog-to-digital conversion module,serial communication module,thermocouple cold end compensation module,power module.The STC microcontrollers are mounted on the shearer's rocker in a modular manner.Each module contains multiple sensor analog interfaces and their data conversion.The data is converted and processed one after the other.The data storage unit stores the data collected and processed by the single-chip computer,records the data change of the specific position of the shearer's rocker arm for a certain period of time,and provides the monitoring data for the safety early warning function of the monitoring system.Front-end module to collect the data transmitted through the RS485 communication to the host computer touch screen for real-time display and fault analysis.The software programming of the lower computer mainly includes multi-channel analog signal data acquisition,A/D conversion,data processing,fault detection,serial communication and other procedures.The system of the host computer is based on the MCGS configuration software touch screen,including the sensor calibration module,data display module,historical data,curve query module,early warning parameter setting module and alarm module.The touch screen according to Modbus communication protocol to achieve the next bit with the serial communication.The touch screen realizes serial communication with the lower computer.In this paper,the hardware circuit design and debugging of the monitoring system,the software programming and debugging of the slave computer,the interface design and data processing of the upper computer touch screen are described.The monitoring system achieved the user's functional requirements of the system.