Research On Self-powered Wireless Sensor Nodes For Scraper Chain Tension Monitoring

Scraper conveyor is an important equipment for coal transportation in comprehensive coal face of mine.Scraper chain is the key component of scraper conveyor.The tension change of scraper chain is complicated and difficult to control effectively,which leads to chain breaking,chain skipping of the scraper conveyor.By monitoring the tension of scraper chain,it can play a guiding role in fault prediction and protection of scraper conveyor.At present,the tension monitoring of scraper chain mostly depends on manual inspection,motor status monitoring and load monitoring.All these methods have poor precision and also hysteresis,so it is unable to effectively monitor the tension change of scraper chain in real time.The application of wireless sensor nodes in scraper chain tension monitoring can meet the requirements of realtime monitoring,high precision and high reliability.Finding the way to combine the nodes with the scraper chain and solve the problem of energy supply of mobile nodes is worth further study to effectively monitor the tension of scraper chain.Therefore,combined with the working principle and the actual working environment of scraper conveyor,this paper proposes a method of self-powered wireless sensor nodes to monitor the scraper chain tension,and considers embedding it into the scraper to achieve the purpose of effective real-time monitoring of scraper chain tension.The main contents of this paper are as follows:(1)Design of scraper chain tension monitoring scheme.This chapter expounds the working principle of scraper conveyor,and proposes the overall scheme of scraper chain tension monitoring according to the demand.By embedding the wireless sensor nodes into the scraper,the scraper chain tension information can be collected in real time.In order to ensure the endurance of the nodes,the energy supply module is designed to supply power for the nodes.In addition,the hardware architecture of the nodes is built,and the Sub-1GHz technology is determined as the wireless communication technology of the scraper chain tension monitoring nodes.(2)Design of the software and hardware of the nodes.Firstly,the main control module,data acquisition module,wireless communication module and power supply module of the nodes hardware are designed,and the PCB of the nodes is designed and manufactured.Then the control schemes of node initialization,low power consumption mode,data acquisition and processing and data transmission are designed.Finally,the upper computer software of remote monitoring terminal is developed through Lab VIEW software.(3)Design of the energy supply module.Firstly,the energy demand of the node is analyzed.Combined with the working principle and the actual working environment of scraper conveyor,an energy collection device based on friction wheel drive is designed.And a specific installation scheme is designed based on the embedded installation requirements of energy collection device.Aiming at the problems of intermittent operation and unstable output voltage of the energy collection device,a dual energy source is proposed and the energy management circuit is designed in order to ensure the continuous and stable energy supply of the energy supply module for the node.(4)Test and analysis of the node performance.Firstly,the basic functions of the nodes are tested.The experimental results show that the nodes realize the functions of data acquisition,processing and wireless transmission.And the upper computer software meets the demand of data display,data storage and data alarm.Then,the power consumption of the nodes is tested,and the actual power consumption of the nodes is consistent with the estimation in this paper.Then the performance of the energy supply module is tested,and the results show that the energy supply module can continuously and stably supply energy for the nodes.Finally,the endurance capability of selfpowered nodes is analyzed,and the experimental results show that the endurance capability of self-powered nodes is five times higher than that of ordinary node.This paper includes 67 figures,16 tables,and 101 references.