基于功能分析的带式输送机自动巡检机器人设计

Design of automatic inspection robot for beltconveyor based on functional analysis

带式输送机具有长距离连续运输等优点,成为运输煤炭等矿山物料的重要设备。在长时间连续运行过程中,带式输送机关键部件的性能退化会引发输送带打滑、跑偏和断带等故障,迫切需要对其工作状态进行实时监测。针对传统带式输送机自动巡检系统上下坡驱动打滑、平稳性差等问题,设计了一种基于轨道摩擦和齿轮齿条啮合混合驱动的自动巡检机器人。基于功能分析,设计了巡检机器人的总体方案,提出了水平运动时采用行走轮和轨道的摩擦式驱动和上下坡运动时采用齿轮齿条啮合驱动的两阶段驱动方式,增加了巡检机器人的爬坡能力,避免了传统巡检装置存在的上下坡打滑的不足。考虑到带式输送机恶劣的巡检工况,详细设计了巡检机器人的驱动系统和行走系统等机械结构,并采用Creo软件建立了巡检机器人的三维模型。针对巡检机器人的控制系统实现的功能,完成了巡检机器人的控制系统硬件选型和控制系统程序的流程图设计,并计算出巡检机器人的续航时间。采用ANSYS软件对底板和托架进行了有限元分析,完成了底板轻量化设计并对底板和托架的强度进行了校核分析。采用ADAMS软件对巡检机器人的运动过程进行了仿真分析,运动学仿真结果表明:巡检机器人能够顺利实现水平运动和上下坡运动的无干涉平稳切换。

Belt conveyor has the advantages of long-distance continuous transportation and has become an important equipment for the transportation of coal and other mining materials. During the long-term continuous operation, the performance degradation of key components of belt conveyor will lead to belt slippage, deviation, and belt breakage. In view of the problems of slippage and poor stability of the upper and lower slope drive of traditional automatic inspection system for belt conveyor, an automatic inspection robot based on the mixed drive of track friction and gear-rack meshing was designed. Based on the function analysis, the overall schemes of inspection robot were designed and the two-stage driving mode of the friction drive of the walking wheel and the track was proposed for horizontal movement and the two-stage drive mode of the gear-rack meshing drive was adopted for the up-and-down slope movement, which increases the inspection robot’s capabilities. The climbing ability avoids the insufficiency of slipping up and down slopes existing in the traditional inspection device. Considering the harsh inspection conditions of the belt conveyor, the mechanical structures such as the driving system and the walking system of inspection robots were designed in detail, and Creo software was used to establish three-dimensional model of inspection robot. According to the functions realized by the inspection robot’s control system, the hardware selection of the inspection robot’s control system and the flow chart design of program of the control system of inspection robot were completed, and the endurance time of inspection robot was calculated. ANSYS software was used for finite element analysis of the baseplate and the bracket. The lightweight design of the base plate was completed, and the strength of the baseplate and the bracket was checked and analyzed. ADAMS software was used to simulate and analyze the motion process of inspection robot, and the results of kinematics simulation show that inspection robot can smoothly switch between horizontal motion and up-slope motion without interference.