用于带式输送机自检托辊的能量收集器设计

Design of energy harvester for self-checking roller in belt conveyor

  • 摘要: 带式输送机自检托辊将无线传感器节点安装在托辊内部,用于采集并无线传输温度与振动信号,为煤矿带式输送机托辊健康检测提供了一种新的思路。针对密闭托辊内无线传感器节点的能量供给问题,设计了一种基于Halbach永磁体阵列的能量收集器。介绍了能量收集器的结构设计,根据无线传感器节点实际能耗及能量管理电路效率分析了供能需求;采用COMSOL Multiphysics 5.5对能量收集器进行有限元分析,验证了Halbach永磁体阵列用于小型旋转体能量收集器时较常规永磁体阵列具有明显优势,并分析了气隙厚度、永磁体厚度、转子速度对能量收集器发电性能的影响,得出通过减小气隙厚度、增大永磁体厚度、提高转子速度等方式可有效提高能量收集器感应电压的结论;基于能量收集器供能需求分析、安装空间要求及有限元分析结果,优化了能量收集器参数,并制作了样机进行试验,结果表明:在5 r/s托辊转速下,能量收集器感应电压有效值为4.77 V,最大功率为171.33 mW,功率密度为6.78 mW/cm3,满足无线传感器节点能耗需求(165.722 mW)。

     

    Abstract: The belt conveyor self-checking roller installs wireless sensor nodes inside the roller to collect and wirelessly transmit temperature and vibration signals, which provides a new idea for the health checking of coal mine belt conveyor rollers. In order to solve the energy supply problem of the wireless sensor nodes in the closed roller, an energy harvester based on the Halbach permanent magnet array is designed. This paper introduces the structural design of the energy harvester, and analyzes the energy supply requirements based on the actual energy consumption of the wireless sensor nodes and the efficiency of the energy management circuit. COMSOL Multiphysics 5.5 is used for finite element analysis of the energy harvester to verify that Halbach permanent magnet array has obvious advantages over conventional permanent magnet array when used in small rotating body energy harvesters. The effect of air gap thickness, permanent magnet thickness and rotor speed on the power generation performance of the energy harvester is analyzed. And it is concluded that the induced voltage of the energy harvester can be increased effectively by reducing the air gap thickness, increasing the permanent magnet thickness and increasing the rotor speed. Based on the analysis of energy supply demand, installation space requirement and finite element analysis, the parameters of the energy harvester are optimized, and a prototype is built for testing. The results show that at 5 r/s rotor speed, the effective value of the induced voltage of the energy harvester is 4.77 V, the maximum power is 171.33 mW, and the power density is 6.78 mW/cm3, which meets the energy consumption requirements (165.722 mW) of wireless sensor nodes.

     

/

返回文章
返回