基于FBG传感器的带式输送机故障监测研究  

Research on fault monitoring of belt conveyor based on FBG sensor

作　　者：方新秋[1,2] 吴洋 宋扬[1,2] 陈宁宁 丰宇龙 冯豪天[1,2] 贺德幸 乔富康 FANG Xinqiu;WU Yang;SONG Yang;CHEN Ningning;FENG Yulong;FENG Haotian;HE Dexing;QIAO Fukang(School of Mines,China University of Mining and Technology,Xuzhou 221116,China;Research Center of Intelligent Mining,China University of Mining and Technology,Xuzhou 221116,China)

机构地区：[1]中国矿业大学矿业工程学院,江苏徐州221116 [2]中国矿业大学智能化开采研究中心,江苏徐州221116

出　　处：《煤炭科学技术》2025年第1期326-340,共15页Coal Science and Technology

基　　金：国家自然科学基金面上资助项目(52474183);江苏省研究生科研与实践创新计划资助项目(KYCX23-2775)。

摘　　要：带式输送机的故障监测有助于预防安全事故、提高生产效率以及实现设备智能化运行。从带式输送机常见故障分析、综合保护系统组成、光纤型传感器阵列设计与分析、核心敏感元件设计与选材等方面,对基于FBG传感器的带式输送机故障监测进行了深入研究。首先针对传统监测手段无法定量感知、实时性不足、数据融合能力薄弱等问题,提出了一种基于光纤光栅(FBG)的带式输送机综合保护系统,明确了光纤型传感器阵列的设计是系统搭建的重要前提。其次,在分析带式输送机常见故障形成原因和表现形式的基础上,以FBG-等强度悬臂梁为核心敏感元件设计了一系列故障监测传感器,组成了带式输送机综合保护系统的光纤型传感器阵列,实现了故障的实时定量监测。接着,通过理论分析和Ansys有限元仿真,对FBG-等强度悬臂梁的尺寸结构设计和材料选择进行了深入研究,在传感模型中分析了灵敏度和精度的影响因素,并据此确定了敏感元件的结构尺寸,优选了尼龙6作为制作材料。最后,通过试验对FBG-等强度悬臂梁的结构有效性、灵敏度和稳定性进行了验证。在灵敏度试验中,敏感元件表现出良好的线性响应特性,理论灵敏度S=52.9780Nnm,实际灵敏度S^(*)=38.1157 Nnm;在重复性试验中,平均重复性误差仅为1.002%,表现出良好的重复性和稳定性;温度敏感性试验和温度补偿试验则验证了光纤光栅在温度测量中的线性相关性,从而进一步揭示了温度补偿对提升传感灵敏度的必要性,即便在微小温度变化环境下,补偿机制仍能有效提高灵敏度0.6%。所设计的光纤型传感器阵列解决了现有带式输送机运行故障无法实时定量感知的问题,为实现设备智能化感知与控制提供了坚实的数据基础。研究成果不仅能有效降低带式输送机故障率,提高生产效率,更推动了煤矿行业向自动化、智能化�The fault monitoring of belt conveyors serves as a pivotal tool in preventing safety incidents,enhancing production efficiency,and facilitating the intelligent operation of equipment.This comprehensive study delves into the multi-sensor fault monitoring of belt conveyors utilizing Fiber Bragg Gratings(FBGs),examining aspects such as common fault analysis,the composition of integrated protection systems,the design and analysis of fiber-optic sensor arrays,and the design and material selection of core sensing elements.Firstly,to address the shortcomings of traditional monitoring methods,including the inability to quantify faults,inadequate real-time performance,and weak data fusion capabilities,an FBG-based integrated protection system for belt conveyors is proposed.This system underscores the cruciality of designing a fiber-optic sensor array as a fundamental prerequisite for system establishment.Secondly,building upon an analysis of the root causes and manifestations of common faults in belt conveyors,a series of fault monitoring sensors are devised,with FBG-based equal-strength cantilever beams serving as the core sensing elements.These sensors constitute the fiber-optic sensor array within the integ-rated protection system,enabling real-time and quantitative fault monitoring.Thirdly,theoretical analyses and Ansys finite element simula-tions are conducted to thoroughly investigate the dimensional design and material selection of FBG-based equal-strength cantilever beams.The influencing factors on sensitivity and accuracy are analyzed within the sensing model,guiding the determination of the structural di-mensions of the sensing elements.Nylon 6 is selected as the optimal material for fabrication.Finally,experimental validation is performed to assess the structural effectiveness,sensitivity,and stability of the FBG-based equal-strength cantilever beams.In sensitivity tests,the sensing elements exhibit exceptional linear response characteristics,with a theoretical sensitivity of 52.9780 N/nm and an actual sensitiv

关 键 词：光纤光栅 等强度悬臂梁 温度补偿 光纤型传感器阵列 带式输送机综合保护 

分 类 号：TH712[机械工程—测试计量技术及仪器]