Real time monitoring and protection of steel wire ropes
1.Application background
With the increasing application of overhead passenger devices in coal mines,their safe operation status has also received more and more attention from coal mine users.
As a key equipment of the overhead passenger device,the traction steel wire rope is prone to surface rust in humid tunnel environments.However,long-term operation of the equipment can easily cause the steel wire rope to wear and break due to excessive fatigue.If the steel wire rope breaks to a certain extent and is not replaced in time,it will cause damage to the overhead passenger device equipment and personal injury,The successful development of an online detection system for overhead passenger device steel wire ropes will completely solve this problem.
The real-time monitoring and protection device for the steel wire rope of the overhead passenger device monitors the operation status of the traction steel wire rope of the overhead passenger device in real time.On the one hand,it fundamentally eliminates the hidden danger of accidents caused by the wear and breakage of the steel wire rope,ensuring the safe operation of the overhead passenger device;On the other hand,scientifically extending the service life of steel wire ropes,saving rope replacement time,and reducing rope costs;Improve the efficiency of wire rope inspection and reduce the labor intensity of wire rope inspection.
2.System composition
The real-time monitoring and protection device for steel wire ropes consists of sensors for mining intrinsic safety steel wire rope flaw detection,magnetic loading devices,mining explosion-proof and intrinsic safety sub stations,mining explosion-proof encoders,mining explosion-proof PLC control boxes,and mining intrinsic safety operation platforms.
3.Function
The steel wire rope real-time monitoring and protection device monitors the wear and breakage of the overhead passenger device's traction steel wire rope in real time online,and provides voice alarm prompts based on the wear and breakage of the steel wire rope.At the same time,the position and degree of damage of the steel wire rope wear and breakage are displayed on the operation console.
When the wire rope is broken by 5%,the control system will issue an alarm and a voice prompt saying"Wire rope is broken by 5%,please prepare to replace it".
When the wire rope is broken by 10%,the control system will issue an alarm and a voice prompt saying"The wire rope has broken by 10%,please confirm that the replaced wire rope is ready".
3.3 When the wire rope is broken by 15%,the control system issues an alarm and a voice prompt saying"The wire rope is broken by 15%,please replace the wire rope",and the overhead passenger device stops running.It can only be started after replacing the new wire rope.
Detection and protection of braking force on wheel brakes
1.Application background
At present,the overhead passenger devices are generally equipped with wheel brakes with built-in disc springs,and the braking performance of the wheel brakes plays a decisive role in the safe and reliable operation of the overhead passenger devices.Under certain conditions such as braking radius and friction coefficient,the braking positive pressure of the wheel brakes is a key indicator that determines the braking performance of the brakes.
The braking force detection device developed by our company can detect the positive braking pressure of the wheel brake in real time,realizing the detection and protection of the braking performance of the wheel brake,ensuring the safety of personnel.
2.Function implementation
2.1 The braking force detection device detects the positive pressure of the brake on the brake disc and outputs the corresponding electrical signal.The electrical signal is converted into a CAN bus signal and transmitted to the PLC,and the braking force of the wheel brake is displayed in real-time through the touch screen.
2.2 When there are two situations,the electronic control system will sound a voice fault alarm and the overhead passenger device will not be able to start:the first is that before the overhead passenger device starts,the braking force is lower than the set value;The second type is that after the electronic control system sends a command to activate the wheel brake,the electronic control system detects that the braking force is higher than the set value.
Oil change reminder
1.Function
During the use of auxiliary transportation equipment in mines,if the lubricating oil is not replaced according to the prescribed time,the gear wear of the reducer will accelerate due to the decrease in the viscosity of the oil.In severe cases,it may cause accidents such as flying cars and injuring people,such as the accident of the overhead passenger device in Lianhuashan,Shandong.
The"oil change reminder function"effectively solves this problem by setting the oil change time for the gearbox of the auxiliary transportation equipment in the electronic control system,and providing voice reminders and text displays.When the gearbox has reached the set oil change time but has not been changed,the system automatically stops and locks.
2.Operating instructions
2.1 Set the oil change time based on the reducer used in the auxiliary transportation equipment of the mine.
2.2 The electronic control system will provide a voice warning 168 hours in advance to remind users to prepare for the gearbox oil change.The reminder will be given every 24 hours,and the countdown to the oil change time will be displayed on the left side of the touch screen of the electronic control system.This will be illustrated using the example of a coal mine overhead passenger device.
When the countdown to the oil change time equals 0,the overhead passenger device will automatically stop and lock,the electronic control system will provide voice prompts,and the touch screen interface will jump to display the relevant requirements for the gearbox oil change.
The oil change of the overhead passenger device gearbox is completed,and the electronic control system automatically enters the timing of the next round of gearbox oil change.
Mandatory routine inspection
1.Function
At present,in the daily management of auxiliary transportation equipment in mines,the maintenance process is often very arbitrary and cannot achieve systematic and targeted inspection of overhead passenger devices;The main operating equipment of auxiliary transportation equipment in mines(such as reducers)may experience wear and tear during continuous operation,posing safety hazards.If not inspected in a timely manner,it may lead to production accidents and threaten the personal safety of production personnel.
The addition of a"mandatory routine inspection"function in the electronic control system provides users with detailed maintenance and troubleshooting items,while achieving the purpose of mandatory equipment shutdown for inspection.Users can start the equipment normally only after confirming that all items meet the requirements of the maintenance and troubleshooting items according to the daily inspection items of the mine auxiliary transportation equipment set by the electrical control system.
2.Operating instructions
2.1 Users set mandatory routine inspection times(such as 0:00 to 23:00)based on the usage of auxiliary transportation equipment in the mine,using the example of overhead passenger devices in coal mines.
2.2 The operation interface of the overhead passenger device monitoring system displays the countdown to routine inspections,and a voice warning is issued one hour before the set time.The system reminds users to check the countdown time for routine inspections and prepare for equipment maintenance.
2.3 When the countdown time for mandatory routine inspection is equal to 0,the overhead passenger device will stop and lock,and the system will voice and display the items that the overhead passenger device needs to be repaired,This includes inspections related to the safe operation of overhead passenger devices,including oil temperature in the fuel tank,oil temperature in the gearbox,oil level in the gearbox,brake clearance at the wheel edge,levelness between the steel wire rope and the driving wheel,speed protection,slope change point rope drop protection,and emergency stop protection along the line.
2.4 After the mandatory routine inspection is completed,the overhead passenger nuclear device can be started according to the normal operating sequence,and the timing of the next round of mandatory routine inspection of the overhead passenger device can also begin.
Black Box-Operating Data Recorder(Patent No.201420565681.4)
1.Function
With the demand for coal mine automation control,more and more automation control equipment is being used in mines.Automation control equipment not only brings management convenience to mining enterprises,but also buries safety hazards for coal mine accidents.In recent years,coal mine accidents caused by equipment reasons have been increasing year by year.After accidents occur,equipment is often damaged,and the cause of equipment failure is difficult to find.
The application of operational data storage recorders in mining control equipment effectively solves this problem.On the one hand,it has a large capacity of data storage function,which can store and record 30 days of operational information,safety protection information,and operation control information of the equipment.The recorded information only has a reading function,and there is no legal person to change or delete it,ensuring the validity,authenticity,and real-time nature of the data,Once an accident occurs due to equipment failure,the operating parameters of the entire equipment involved in the accident can be identified,thereby identifying the cause of the accident;On the other hand,in the event of uncontrollable external disasters,the device is not easily damaged,so running a data storage recorder is called a"black box".
2.Performance characteristics
2.1 By recording the most effective and authentic operational information,it helps to improve the level of equipment operation management and achieve the goal of comprehensive monitoring of equipment operation status;
2.2 By recording real-time operation control signals and safety protection information,it is convenient for timely elimination of hidden faults and effective analysis of accident causes.
Chair blocking device(patent number:ZL20152045465.9)
Using the principle of backstop,when the"monkey car"experiences flying or slipping,the suspension chair is forcibly blocked,so that one or at most two people can be stopped and stopped within every two crossbeams,in order to avoid the collision of miners during flying or slipping,resulting in group deaths and injuries.It can effectively protect the personal safety of miners when the current three-level braking devices(high-speed braking,safety braking,and wire rope braking)lose their braking force,and can be regarded as the last line of life protection for miners riding the"monkey car".
Wear detection of wheel lining(patent number:201521111011.3)
The wheel lining wear detection device adopts high-frequency data communication technology and radio frequency wireless communication technology to detect the degree of wear of the wheel lining of the driving wheel and supporting rope wheel device of the coal mine overhead passenger device in real time,preventing excessive wear of the wheel lining and causing dangerous accidents such as wire rope slipping and falling,thereby reducing the safety operation risk of passengers and equipment.When the electronic control device detects that the wheel liner has reached its limit of wear,a voice alarm will sound"Drive wheel liner wear has reached its limit,please replace the wheel liner in a timely manner"to control the overhead passenger device to protect the parking.
Wire rope braking device(patent number:ZL201220418988.X)
Using the principle of wedge slider clamping,powered by an explosion-proof thruster,the steel wire rope entering and exiting the driving wheel is braked,and the braking efficiency is 100%.When the"monkey car"is running,the possible situations that may occur are:
1.When the low-speed safety brake loses braking force,
2.When the friction between the steel wire rope and the driving wheel is insufficient,
3.When the drive wheel breaks or falls off;
After the above situations occur,serious accidents such as speeding and slipping may occur.The wire rope brake can effectively prevent accidents by braking the wire rope.This is the last braking device of the"monkey car"and can be regarded as the protective deity for miners riding the"monkey car".
