| As the key equipment for mechanized coal mining in fully mechanized mining face,scraper conveyor plays an important role in transporting coal,providing running track for shearer,and providing shift support for hydraulic support.Scraper conveyor chain is connected to sprocket,scraper,and direct contact with the raw coal,its tension directly reflects the running status of the conveyor.The time-varying characteristics of chain tension and the difficulty of effective control often lead to the trouble of scraper conveyor such as chain-jumping,blocked-rotor and chain-breaking,but there is still a lack of mature technology to monitor the chain tension effectively,which restricts the control effect of the chain tension.In this paper,according to the actual working condition of the scraper conveyor,the chain tension of the scraper conveyor was analyzed and calculated,the chain tension was simulated by the virtual prototyping technology,the distribution of the chain stress and deformation was obtained through the finite element analysis,and the chain tension monitoring scheme of the scraper conveyor was designed to realize the real-time monitoring of the chain tension.The main content and research results of this paper are listed as follows:(1)By analyzing of the basic structure and working principle of the scraper conveyor,the pretension of the scraper conveyor was analyzed and calculated,the calculation method of the airborne coal quantity of the scraper conveyor was proposed,and the tension of the scraper chain was analyzed and calculated by the point by point calculation method for no-load operation and uniformly distributed load,as well as,polygonal effect of chain drive system was analyzed.(2)The 3D solid model of scraper conveyor was established based on Creo,the dynamic simulation model of chain transmission system of scraper conveyor was established by ADAMS,and the simulation model was simplified according to the purpose of the research and the characteristics of chain transmission system of scraper conveyor.By simulating different working conditions,the variation rule of the tension of the scraper chain under the corresponding working conditions was analyzed,and the dynamic load of sprocket and scraper chain was obtained,which provided load basis for the finite element analysis of the sprocket transmission system.(3)The finite element analysis of the key components of chain transmission system was carried out by ANSYS,and the distribution of stress and deformation was obtained,which provided a strategy for the installation of strain sensors.According to the running characteristics of the scraper conveyor,the chain tension monitoring scheme of the scraper conveyor was designed,which can quickly and effectively detect the chain tension information of the scraper conveyor,and at the same time,the structural components involved in the monitoring scheme were checked for strength and fatigue life.(4)The experimental platform for the chain tension monitoring system of scraper conveyor was built,and the ground experiment was carried out in Jiangsu Collaborative Innovation Center of Intelligent Mining Equipment.The experimental results showed that the chain tension monitoring scheme of the scraper conveyor was feasible and can realize real-time acquisition,wireless transmission and remote monitoring of the chain tension of the scraper conveyor.The change trend of chain tension was consistent with the dynamic simulation results of chain drive system. |
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