| The pipe belt conveyor is widely used in docks,power plants,mines and other important industries based on its advantages of strong conveyor capacity at large angles,flexible line layout,and sealed and environmentally-friendly twoway delivery of materials.With its development towards long distances and large volumes,the pipe belt conveyor has become an extremely important continuous transportation device.As an important part of the pipe belt conveyor,idlers are plentiful.They are prone to wear and break during the operation of conveyors,and in severe cases can catch fire.Therefore,it is particularly important to detect and maintain the idler status.Currently,status detection and maintenance replacement of idlers are not integrated.The mode of status detection of idlers using inspection robots needs to build new walking tracks and is limited to idler detection.If repairs are required,the technician still needs to carry tools or arrive at the designated fault point to perform repairs via the idler replacement device,which is time-consuming and inefficient.Moreover,existing idler replacement devices are only applicable to ordinary belt conveyors and not to hexagonal idler structures of pipe belt conveyors.During the maintenance of the idler,the pipe belt conveyor still needs to be shut down.In order to avoid downtime for maintenance,factories often set up two parallel conveyors at the same time.When one conveyer is being maintained,the other conveyer can work directly,which is extremely costly.Based on this,it is necessary to develop an intelligent operation and maintenance system for idlers of pipe belt conveyor that can detect idlers operation and automatically maintain them under working conditions,and analyze the operation and maintenance devices that complete main functions in the operation and maintenance system.Its research contents include the following points:First,the intelligent operation and maintenance system of idlers of pipe belt conveyor is studied and designed based on the functional requirements of idler operation and maintenance.The contents of idler detection and maintenance by pipe belt conveyor inspectors are analyzed,the design requirements of the operation and maintenance system are summarized,and the design scheme of the intelligent operation and maintenance system for idlers is proposed.Based on the design scheme of idler intelligent operation and maintenance system,the structure design and three-dimensional modeling of idler operation and maintenance device in the scheme are completed,and the information acquisition module,communication module and control and decision module of idler intelligent operation and maintenance system are analyzed and studied.The work process of automatic detection and maintenance of idlers in pipe belt conveyors by the Idler Smart Operations and Maintenance System is described in detail.Second,according to the characteristics of the idler and its truss frame,the structure of the idler operation and maintenance device is designed and analyzed,and the feasibility and rationality of the device design is verified.The size design parameters of the vehicle body of the operation and maintenance unit were determined and the range of action of the conveyor belt lifting arm of the operation and maintenance unit was analyzed.Combined with the layout and position of window frame idlers in the pipe belt conveyor,the rotational speed and joint variable range of each joint of the replacement arm of the idlers were given.On this basis,the analysis and calculation of the main working mechanism of the mechanical system of the operation and maintenance device are completed,including the driving force analysis of the operation and maintenance device running in the horizontal straight section and inclined section of the truss,the calculation of the maximum torque of each joint of the mechanical arm of the idler replacement,the selection and calculation of the driving motor,the joint motor of the mechanical arm and the power battery.Analysis of the load on each hydraulic cylinder of the conveyor belt lifting arm and the driving force required for the idler to replace the mechanical claw electric push rod during a particular work phase.Third,the kinematic and mechanical simulation analysis of the mechanism of idler operation and maintenance is performed according to the working process of idler detection and maintenance.The ADAMS simulation model is established to simulate the operation and maintenance device running on the conveyor truss,and the working process of the conveyor belt lifting bearing section and the return section of the conveyor belt when parking on the truss at different inclination angles verifies the rationality of the design of the traveling mechanism and the conveyor belt lifting arm of the developed operation and maintenance device,and can realize the stable operation of the whole machine,and at the same time analyze the load change curve and law of each hydraulic cylinder of the lifting arm under different working conditions.The forces of each member of the operation and maintenance device have been clarified,the loads and constraints of each component of the operation and maintenance device are analyzed,and the static analysis of each structural component of the device is carried out using ANSYS Workbench software,and improvement measures are proposed when the strength of each structure does not exceed the material yield limit and the maximum deformation is more acceptable than the corresponding component. |
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