Design and research of built-in wireless strain acquisition card for tracked traveling structure

doi:10.3785/j.issn.1006-754X.2024.03.151

Chinese Journal of Engineering Design

2024, Vol. 31

Issue (3): 393-401 DOI: 10.3785/j.issn.1006-754X.2024.03.151

Mechanical parts and equipment design

Design and research of built-in wireless strain acquisition card for tracked traveling structure

Guozhu YIN¹(

),Hong ZHANG¹(

),Yang SONG²,Jingyu WANG¹,Jiaqi SONG¹

^1.School of Mechanical Engineering, Taiyuan University of Science and Technology, Taiyuan 030024, China
^2.Taiyuan Research Institute Company Limited, China Coal Technology and Engineering Group, Taiyuan 030006, China

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Abstract

Aiming at the problem that it is difficult to obtain the track load of coal mine tracked tunneling robots during driving, a set of four-channel wireless strain acquisition card suitable for collecting dynamic characteristics of tracked traveling structure was designed based on the strain effect of resistive strain gauges and the measurement circuit. Firstly, the circuit and working principle of the strain acquisition card were analyzed. Then, two pairs of strain gauges were symmetrically arranged on the test template, and the strain data collected by DH5902N rugged data acquisition and analysis system was used as the standard to calibrate the sensitivity of four channels in the strain acquisition card through the combination of simulation and test. Finally, the strain acquisition card was integrated and packaged in the tracked traveling structure, and the temperature variation rule of the strain acquisition card under continuous operation in the package environment was discussed. The results showed that the designed strain acquisition card could collect the strain signal of four channels at the same time. Its maximum sampling frequency was 1 000 Hz, transmitting power was 4.5 dBm, and strain acquisition error was less than 5×10^-6. The temperature of the strain acquisition card was stable at 34.58 ℃ after 34.7 h continuous operation in the package environment, which could realize the multi-degree-of-freedom strain signal detection for the tracked traveling structure. The research results provide technical support for real-time acquisition of the dynamic load of tracked traveling structures and the reliability analysis and fault prediction of tunneling robots.

Key words： tracked traveling structure strain acquisition card calibration package

Received: 20 April 2023 Published: 27 June 2024

CLC:

TH 113

Corresponding Authors: Hong ZHANG E-mail: 19581596040@163.com;hexie007@163.com

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Cite this article:

Guozhu YIN,Hong ZHANG,Yang SONG,Jingyu WANG,Jiaqi SONG. Design and research of built-in wireless strain acquisition card for tracked traveling structure. Chinese Journal of Engineering Design, 2024, 31(3): 393-401.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2024.03.151 OR https://www.zjujournals.com/gcsjxb/Y2024/V31/I3/393

履带行驶结构的内置式无线应变采集卡设计研究

针对煤矿履带掘进机器人在行驶过程中难以获取履带载荷的问题，基于电阻应变片的应变效应和测量电路，设计了一套适用于采集履带行驶结构动态特性的四通道无线应变采集卡。首先，分析了应变采集卡的电路和工作原理。然后，将2对应变片对称布置在试样板中，以DH5902N坚固型数据采集分析系统所采集的应变数据作为标准，通过仿真与试验相结合的方法对应变采集卡4个通道的灵敏度分别进行了标定。最后，将应变采集卡集成封装后内置于履带行驶结构中，并探讨了应变采集卡在封装环境下连续工作时的温度变化规律。结果表明，所设计的应变采集卡可同时采集4个通道的应变信号，其最高采样频率为1 000 Hz，发射功率为4.5 dBm，应变采集误差不超过5×10^-6。该应变采集卡在封装环境下连续工作34.7 h后的温度稳定在34.58 ℃左右，可实现履带行驶结构的多自由度应变信号检测。研究结果为履带行驶结构动态载荷的实时采集以及掘进机器人的可靠性分析和故障预测提供了技术支撑。

关键词： 履带行驶结构, 应变采集卡, 标定, 封装

Fig.1 Basic structure of direct current bridge

Fig.2 Working principle of strain acquisition card

Fig.3 Circuit diagram of strain acquisition card

Fig.4 Strain acquisition card calibration device

Fig.5 Paste position of strain gauge on test template

Table 1 Coordinate of paste position of strain gauge

Fig.6 Strain simulation result of test template (circular hole 1 fixed and applied with external force of 41.16 N)

Table 2 Strain simulation results of test template under different fixed positions and applied external force

Table 3 Calibration test measurement data for CH1 and CH2 channels of strain acquisition card

Table 4 Calibration test measurement data for CH3 and CH4 channels of strain acquisition card

Fig.7 Comparison of acquired strain by DH5902N and simulated strain

通道	拟合函数	决定系数R²
CH1	$y 1 = 3.640 ? x 1 - 4.394$	0.949
CH2	$y 2 = 3.886 ? x 2 - 1.161$	0.994
CH3	$y 3 = 5.129 ? x 3 + 5.885$	0.998
CH4	$y 4 = 4.015 ? x 4 - 0.758$	0.978

Table 5 Fitting function of acquired data of strain acquisition card and DH5902N

Fig.8 Fitting results of acquired data of strain acquisition card and DH5902N

Fig.9 Comparison of acquired data by calibrated strain acquisition card and DH5902N

Fig.10 Strain acquisition card package structure

Fig.11 Package position of strain acquisition card in tracked traveling structure

Table 6 Power consumption and heat generation of each component of strain acquisition card

Fig.12 Temperature variation rule of strain acquisition card

Fig.13 Temperature cloud map of strain acquisition card at t=34.7 h


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