钢丝绳芯输送带接头变形的定量分析及断带预警研究

Splice is the weakest region of the steel cord conveyor belts. Splice strength reduction which is caused by the splice twitch fault is the basic reason for the belt broken. Splice twitch fault would be embodied by splice deformation. However, there is no quantitative theory analysis evidence to explain the relationships between the splice deformation, splice strength and the belt broken. And these relationships will be researched in this project based on X-ray detection technique, tensile experiment technique and finite element simulation method. Firstly, based on the X-ray detection technique, splice deformation monitoring method and the X-ray dynamic image processing algorithm are proposed to improve the reliability and accuracy of deformation detection. And then, tensile experiment monitored by the X-ray is used to study the mechanical property and splice elongation rule of the splice stretching. Combined with the numerical simulation and mechanical analysis results of the splice deformation, the numerical model of the splice deformation is set up. Moreover, the quantitative relationships between the splice deformation, splice strength and the belt broken are established. Finally, the software for splice deformation monitoring and belt broken early warning is designed, and the experimental study and test are conducted to verify the accuracy and effectiveness of the model. The results of this project can reveal the rule of the splice elongation and the belt broken, and implement the splice deformation monitoring, quantitative analysis and early warning of belt broken for steel cord conveyor belts. And the results can be used as the theoretical basis for the steel cord conveyor belts safety detection, splice maintenance and updating. In this way the belt broken accident, casualty and economic losses can be avoided. Thus, this study has wide application prospect in many fields, such as the coal and mine. And it can also provide reference to optimize steel cord conveyor belts splice design and manufacture.

接头是钢丝绳芯输送带最薄弱的环节。接头抽动故障导致接头强度下降，是造成断带的根本原因。接头抽动故障具体表现为接头变形，接头变形与接头强度及断带的关系一直没有定量的理论分析依据。本项目拟基于X光检测和有限元模拟技术以及拉伸实验方法，对接头变形与接头强度及断带的关系进行定量分析研究，提出基于X光的接头变形监测方法及算法，提高检测的可靠性和准确性；采用X光监测的拉伸实验方法，研究接头拉伸时的力学性能和变形规律，结合对接头变形的数值模拟和力学分析，建立接头变形的数值模型，确定接头变形与接头强度及断带的定量关系；设计接头变形监测与断带预警软件，验证模型的准确性和有效性。项目研究成果能够揭示接头变形演化及断带规律，实现接头变形的监测、定量分析及断带预警，为接头维护和更新提供理论依据，能够预防断带事故发生，避免人员伤亡和经济损失，在煤炭、矿山等领域具有广阔的应用前景，也为优化接头设计和制作提供参考。

输送带是带式输送机牵引和运载的关键部件。接头是钢丝绳芯输送带最薄弱的环节。接头抽动故障导致接头强度下降，是造成断带的根本原因。接头抽动故障具体表现为接头变形，接头变形与接头强度及断带的关系一直没有定量的理论分析依据。本项目基于X光检测技术、拉伸实验方法和有限元模拟技术，对接头变形与接头强度及断带的关系进行了定量分析研究：①研究了钢丝绳芯输送带接头变形的产生机理、特征和监测方法，提出了基于X光的钢丝绳芯输送带接头变形监测方法和基于机器视觉的接头变形监测方法，提高了接头变形检测及接头伸长量计算的可靠性和准确性；②研究了接头拉伸时的力学性能和变形规律，结合对接头变形的数值模拟和力学分析，建立了ST630钢丝绳芯输送带接头的有限元模型，分析了单根和多根钢丝绳接头抽动、拔出及断带的阶段过程以及各阶段的应力分布情况及其对接头强度的影响，得到了接头处钢丝绳不同程度的脱粘、钢丝绳抽动、钢丝绳排布疏密不均及钢丝绳部分缺失等接头变形与接头整体强度之间关系的数值模型，明确了接头变形与接头强度及断带的定量关系，总结了钢丝绳芯输送带接头变形演化及断带规律，以及钢丝绳数目、钢丝绳排布方式、钢丝绳排布间距、钢丝绳排布位置等因素对接头强度影响的规律；③设计了接头变形监测与断带预警软件，验证了接头变形监测方法、数值模型的准确性和有效性。项目成果能够实现接头变形的监测、定量分析及断带预警，可为钢丝绳芯输送带的安全检测、接头维护和更新提供理论依据，延长钢丝绳芯输送带及接头的使用寿命，预防断带事故的发生，避免设备的损坏、停产和人员伤亡，在煤炭、矿山等领域具有广阔的应用前景，也为优化接头设计和制作提供了参考。本项目授权了中国发明专利1项、实用新型专利1项、软件著作权1项，新申请了发明专利2项；发表了学术论文6篇，其中SCI/EI检索4篇；培养了硕士研究生5名。