CN102261988A - Method for testing residual life of crane - Google Patents
Method for testing residual life of crane Download PDFInfo
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- CN102261988A CN102261988A CN2011101042563A CN201110104256A CN102261988A CN 102261988 A CN102261988 A CN 102261988A CN 2011101042563 A CN2011101042563 A CN 2011101042563A CN 201110104256 A CN201110104256 A CN 201110104256A CN 102261988 A CN102261988 A CN 102261988A
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Abstract
The invention relates to a method for testing the residual life of a crane. The method comprises the following steps of: firstly, acquiring wheel pressure standard sample data of cart wheels and trolley wheels of the crane; secondly, establishing finite element analytical models of the cart wheels and the trolley wheels of the crane according to the acquired wheel pressure standard data, and analyzing and optimizing the trolley model wheel pressure of the crane and a cart model wheel pressure output curve of the crane when the crane trolley is positioned at different positions through finite elements; thirdly, acquiring an equivalent weight load spectrum of a structural key measuring point of the crane; and fourthly, calculating the residual life of the crane according to the equivalent weight load spectrum of the structural key measuring point of the crane. The method disclosed by the invention can be used for conveniently measuring points, acquiring the load spectrum of the structural key measuring point of the crane and effectively judging the stressed condition of the crane, thus the field actually-measured complex process and great input of the crane are greatly saved.
Description
Technical field
The present invention relates to the method for testing of crane residual life in the crane technical field of measurement and test, particularly relating to a kind of crane key structure measuring point loading spectrum that is difficult to carry out detection based on wheel load test and finite element analysis obtains and crane force-bearing situation method of testing, it is applicable to obtaining of overhead travelling crane load spectrum and the judge of crane force-bearing situation thereof, and it is obtaining and the judge of crane force-bearing situation applicable to other types Crane Load spectrum also.
Background technology
The steel and iron industry of China in recent decades, industries such as mechanical industry have obtained develop rapidly, large quantities of large bridge cranes have all reached certain tenure of use, how correctly to estimate these crane load-bearing capacity and working conditions, to guarantee safe and reliable use, this is the problem that many users and supervision department are concerned about.In order to address the above problem, be necessary to study the theory and the technology of overhead travelling crane risk assessment and dangerous indication.At present, the overhead travelling crane ageing phenomenon of China is quite serious, and for example the Germany and the Japanese large-scale foundry crane of the introduction of Shanghai Baosteel the eighties have all reached or the approaching time limit that designs, and these equipment all are to be worth several necessarily extremely more than one hundred million units.For many years, the damage of some goliath has caused serious accidents such as enormous economic loss, casualties and environmental pollution.What avoid serious accident is the pressing problem that time and tide wait for no man.These problems are put in (14) great product and the preferential theme of great installation forecasting technique in life span of " National Program for Medium-to Long-term Scientific and Technological Development (2006-2020) " cutting edge technology simultaneously.
Summary of the invention
Technical matters to be solved by this invention provides a kind of method of testing of crane residual life, can make things convenient for measuring point to obtain crane key structure measuring point loading spectrum, effectively the crane force-bearing situation is passed judgment on, thus solve that existing method exists limit, be difficult to carry out the detection of crane key structure measuring point real load spectrum and be difficult to represent the technical barrier of the randomness variation tendency of crane equivalent load because of the field experiment condition with a definite mathematical analysis relational expression.
The technical solution adopted for the present invention to solve the technical problems is: a kind of method of testing of crane residual life is provided, may further comprise the steps:
(1) obtains the wheel load master sample data of crane wheel and monkey wheel, and obtain the curve of output of monkey pressure wheel and monkey crane pressure wheel when the diverse location according to wheel load master sample data;
(2) set up crane wheel and monkey wheel finite element analysis model according to the wheel load master sample data that obtain, and optimize monkey model wheel load and monkey crane model wheel load curve of output when diverse location through finite element analysis;
(3) according to the crane model wheel load curve of output of gained in step (1) and the step (2), be that the geometric relationship of fixing is measured numerical value in conjunction with the crucial measuring point of crane structure and crane wheel position and monkey wheel position again, obtain the equivalent load spectrum of crane structure key measuring point;
(4) calculate the residual life of crane according to the equivalent load spectrum of the crucial measuring point of crane structure.
In the described step (1), be the input of data sample, obtain the curve of output of monkey pressure wheel and monkey crane pressure wheel when diverse location with the different lifted loads of crane.
The input of described sample data is to obtain with the lifted load that crane is under the normal operating conditions.
Also comprise following substep in the described step (4):
(a) equivalent load spectrum of the crucial measuring point of the crane structure that obtains according to step (3) is calculated the Simulating of Fatigue Stress Spectra of the crucial measuring point of crane structure;
(b) from Simulating of Fatigue Stress Spectra, extract the cycle index and the global cycle number of times of stress amplitudes at different levels, stress amplitudes at different levels again with rain flow method;
(c) calculate the equivalent stress width of cloth σ of this Simulating of Fatigue Stress Spectra according to Miner fatigue damage stress amplitude equivalence formula
i
(d) with equivalent stress amplitude σ
iThe computing formula of hardware fatigue surplus life is calculated in substitution:
Can obtain the fatigue surplus life of the crucial measuring point of crane structure.
Beneficial effect
Owing to adopted above-mentioned technical scheme, the present invention compared with prior art, have following advantage and good effect: the present invention is based on crane wheel, monkey pressure wheel master sample data, and crane wheel and monkey wheel finite element analysis model, set up the securing mechanism of the loading spectrum of the type crane, and needn't seek to set up specified lifted load and lifted load and the analytic relationship formula that complexity between corresponding working cycle number of times embarrasses, have convenient test, the characteristics effectively efficiently of realizing.Utilize the crucial measuring point loading spectrum of the crane structure that obtains simultaneously, by calculating the fatigue surplus life that to obtain the loading spectrum of the type crane fast and estimate its girder, thereby save the loaded down with trivial details process and a large amount of input of crane field measurement greatly, realize the purpose of conveniently obtaining loading spectrum and accurately estimating the crane residual life.
Description of drawings
Fig. 1 is a process flow diagram of the present invention;
Fig. 2 is the static wheel system strain curve figure during different wheel load among the present invention.
Embodiment
Below in conjunction with specific embodiment, further set forth the present invention.Should be understood that these embodiment only to be used to the present invention is described and be not used in and limit the scope of the invention.Should be understood that in addition those skilled in the art can make various changes or modifications the present invention after the content of having read the present invention's instruction, these equivalent form of values fall within the application's appended claims institute restricted portion equally.
Embodiments of the present invention relate to a kind of method of testing of crane residual life, this method is utilized the Nonlinear Mapping function of wheel load test and finite element analysis, it is big to adopt the lifted load test to obtain, dolly wheel load data are as data sample, for gathering the crane that same type need be estimated fatigue surplus life later on, big when different lifted load, can be behind the wheel load data test of trundle measuring point to the dolly position location services, realization is obtained the difficult key structure measuring point loading spectrum of testing of crane, thereby calculates the residual life that can obtain crane according to key structure measuring point loading spectrum.
Concrete steps of the present invention may further comprise the steps as shown in Figure 1:
(1) obtains the wheel load master sample data of crane wheel and monkey wheel, and obtain the wheel load curve of output of monkey pressure wheel and monkey crane wheel when the diverse location according to wheel load master sample data.When obtaining wheel load master sample data, the different lifted loads that are under the normal operating conditions with crane are the input of data sample.
(2) set up crane wheel and monkey wheel finite element analysis model according to the wheel load master sample data that obtain, and pass through finite element analysis and optimize monkey model wheel load and monkey crane model wheel load curve of output when diverse location, thereby remedy the deficiency of on-the-spot actual acquired data.
(3) according to the crane model wheel load curve of output of gained in step (1) and the step (2), be that the geometric relationship of fixing is measured numerical value in conjunction with the crucial measuring point of crane structure and crane wheel position and monkey wheel position again, obtain the equivalent load spectrum of crane structure key measuring point.Because the wheel load of crane wheel change to be that wheel load with monkey position and monkey wheel changes and to have corresponding relation, and the lifting campaign of crane generally is logistics campaign clocklike, can know the working cycle of this crane by the wheel load loading spectrum of test, can calculate the working cycle number of times of this crane like this, thereby be that the residual life that calculates crane provides support.
(4) calculate the residual life of crane according to the equivalent load spectrum of the crucial measuring point of crane structure.It specifically comprises following substep:
(a) equivalent load spectrum of the crucial measuring point of the crane structure that obtains according to step (3) is calculated the Simulating of Fatigue Stress Spectra of the crucial measuring point of crane structure;
(b) from Simulating of Fatigue Stress Spectra, extract the cycle index and the global cycle number of times of stress amplitudes at different levels, stress amplitudes at different levels again with rain flow method;
(c) calculate the equivalent stress width of cloth σ of this Simulating of Fatigue Stress Spectra according to Miner fatigue damage stress amplitude equivalence formula
i
(d) with equivalent stress amplitude σ
iThe computing formula of hardware fatigue surplus life is calculated in substitution:
Can obtain the fatigue surplus life of the crucial measuring point of crane structure.Wherein, wherein: N represents the entire life of part, stress level σ at different levels
iUnder the working cycle number be respectively n
i,
Maximum one-level stress point is (σ
1, N
1).
Be that example further specifies the present invention with what test bridging crane main beam below.
1. the wheel load data of the wheel measuring point when gathering the different lifted load of same type
At first paste the test (also can by the pressure transducer acquisition data of wheel correct position are installed) that experimentizes of two foil gauges at a distance of closer locations at the wheel hub of wheel middle part, the STRESS VARIATION of this measuring point under the different loads under the routine work state of investigation crane, respectively wheel is loaded from 20t, 25t, 30t, 35t, 40t, 45t, 50t, 55t, obtain this wheel static wheel system strain variation table 1 and Fig. 2 when different wheel load, carry out analytical calculation, obtain the STRESS VARIATION of wheel measuring point under this stress.
Table 1
2. finite element model
Physical size according to wheel and track is set up computation model.Consider the actual conditions that general present design is used, adopt line contact wheel to set up three-dimensional entity model during analysis, choosing diameter is the crane steel two-wheel edge wheel of 900mm, and supporting with it steel rail for crane comes the artificial line contact.Owing to mainly be the force-bearing situation of investigating wheel integral body, so simplified the mock-up of axletree, supposing that axletree symmetry is external has added a bearing capacity, wheel adopts complete model, and considered rim construction, set up the wheel model with finite element software, guarantee that the tread width of wheel is the same with actual wheel.Equally, simplify the substructure that contacts with track, suppose that axletree is a fixed constraint, select wheel tread to contact as fixed constraint, set up the finite element unit with the line of track.In patran software according to 1: 1 solid modelling, from table 1 and the model that obtains as can be known, the variation of this wheel wheel load has certain linearity and non-linear, two measuring points exist under the identical heap(ed) capacity dependent variable different, the stress that the different measuring points position is described is non-linear, also shows that the equivalent linear of variation tendency changes simultaneously.
3. result of calculation and experimental result comparative analysis, big vehicle model wheel load curve of output when obtaining optimum dolly model wheel load and dolly diverse location
Static wheel system when being carried in the wheel load of 55t is analyzed respectively, obtains the stress distribution cloud atlas of wheel under this stress and the stress deformation cloud atlas of wheel.The model that is obtained by previous step as can be seen, the suffered maximum stress of this wheel is that 47.8MPa, minimum stress are 0.251MPa, this realistic stress, can know near the STRESS VARIATION measuring point 1 and the measuring point 2 again, STRESS VARIATION is to the 12.2MPa interval from 34.8MPa, with the stress curve contrast of Fig. 2, this relatively conforms to measured result, and the accordance of modeling is described.From stress distribution cloud atlas and stress deformation cloud atlas as can be seen whole the and measuring point of wheel deform, bulk deformation be 0mm to 0.0636mm, near the deformation range of measuring point is that 0.039mm is to 0.0289mm.This is that the general measure instrument can't be measured, and can further know more careful information by finite element analysis.Therefore big vehicle model wheel load curve of output in the time of can obtaining optimum dolly model wheel load and dolly diverse location in this way.
4. the position according to crane girder and crane wheel, monkey wheel is that the geometric relationship of fixing is measured numerical value, is to calculate the service of crane girder loading spectrum.
5. in conjunction with the crane wheel during lifted load, the wheel load data of monkey wheel measuring point under the routine work state, and crane girder and crane wheel, monkey wheel position be the geometric relationship of fixing, and carries out the loading spectrum that correlation computations is obtained crane girder.
Can determine this crane institute lift heavy amount by the strain of monkey measuring point, suppose that crane wheel and monkey wheel all are to choose the crane steel two-wheel edge wheel that diameter is 900mm, by the strain of reality test monkey wheel is-68.42 μ ε (might as well suppose that measuring point is consistent with measuring point 1 in the last table 1), the wheel load of monkey wheel is 35.09t as can be known, suppose that the monkey wheel is 4 altogether, might as well suppose that suspension centre is in geometric center, can calculate suffered lift heavy thus is 144.36t (suspension centre can not converse according to definite dolly geometric relationship when geometric center yet), suppose that certain position actual test crane wheel strain of monkey on the cart beam is-120.02 μ ε, the wheel load that can know the crane wheel is 52.17t, while is according to the corresponding monkey location criteria of wheel load sample curve (the corresponding monkey location criteria of the wheel load of the crane wheel sample curve in the time of might as well being assumed to be rated load of crane wheel, the wheel load of supposing crane wheel when the monkey position was in the middle of girder when rated load was 150t is 124.71 μ ε), and actual lift heavy is 144.36t, the strain of the wheel load point position of crane wheel was 144.36/150 * 124.71=-120.02 μ ε when the monkey position was in the middle of girder during then actual lift heavy, the centre position of monkey on the cart beam when knowing actual test lift heavy like this, test strain monkey as can be known less than normal is away from the cart wheel position of test, conversion can be known particular location, just can know carrying and the monkey change in location situation of understanding lift heavy by the several extreme value data of conversion crane wheel like this, can understand the working cycle of this crane, the stressing conditions of the key structure stress point that calculates is by the crane wheel, the geometric relationship of the wheel load of monkey wheel and crane wheel and trundle and key structure stress point converts and obtains, and for example above-mentioned crane suffered moment of flexure in the middle of the girder lower cover is: (qL/2+Q) * and L/2+qL
2/ 2 (q is a uniformly distributed load density, Q is a lift heavy, L is a span), so just can obtain the middle stress (being difficult to test in these actual conditions) of girder lower cover, the loading spectrum of crane girder is by the crane wheel and trundle compressive load spectrum changes formula calculating by the geometric position parameter with working cycle or programming realizes, certainly obtain in the crane model binding analysis that also can under the wheel load situation of knowing crane wheel and monkey wheel, set up by many-body dynamics software (describe geometric position parameter change) and finite element analysis software (learning that the geometric position parameter changes corresponding STRESS VARIATION with working cycle), its essence is equally with working cycle.
6. by the crane girder loading spectrum, calculate the Simulating of Fatigue Stress Spectra of crane girder dangerouse cross-section, utilize rain flow method from Simulating of Fatigue Stress Spectra, to extract the cycle index and the global cycle number of times of stress amplitudes at different levels, stress amplitudes at different levels, with the computing formula of equivalent stress amplitude substitution calculating hardware fatigue surplus life, can estimate the fatigue surplus life of this crane girder.
Be not difficult to find, the present invention utilizes the wheel load loading spectrum of the overhead travelling crane that wheel load test and finite element analysis obtain, can obtain the fatigue surplus life of the loading spectrum and the estimation overhead travelling crane key structure spare of overhead travelling crane structural key measuring point quickly and efficiently, thus the loaded down with trivial details process and a large amount of input of saving the crane field measurement greatly.
Claims (4)
1. the method for testing of a crane residual life is characterized in that, may further comprise the steps:
(1) obtains the wheel load master sample data of crane wheel and monkey wheel, and obtain the curve of output of monkey pressure wheel and monkey crane pressure wheel when the diverse location according to wheel load master sample data;
(2) set up crane wheel and monkey wheel finite element analysis model according to the wheel load master sample data that obtain, and optimize monkey model wheel load and monkey crane model wheel load curve of output when diverse location through finite element analysis;
(3) according to the crane model wheel load curve of output of gained in step (1) and the step (2), be that the geometric relationship of fixing is measured numerical value in conjunction with the crucial measuring point of crane structure and crane wheel position and monkey wheel position again, obtain the equivalent load spectrum of crane structure key measuring point;
(4) calculate the residual life of crane according to the equivalent load spectrum of the crucial measuring point of crane structure.
2. the method for testing of crane residual life according to claim 1, it is characterized in that, in the described step (1), different lifted loads with crane are the input of data sample, obtain the curve of output of monkey pressure wheel and monkey crane pressure wheel when diverse location.
3. the method for testing of crane residual life according to claim 2 is characterized in that, the input of described sample data is to obtain with the lifted load that crane is under the normal operating conditions.
4. the method for testing of crane residual life according to claim 1 is characterized in that, also comprises following substep in the described step (4):
(a) equivalent load spectrum of the crucial measuring point of the crane structure that obtains according to step (3) is calculated the Simulating of Fatigue Stress Spectra of the crucial measuring point of crane structure;
(b) from Simulating of Fatigue Stress Spectra, extract the cycle index and the global cycle number of times of stress amplitudes at different levels, stress amplitudes at different levels again with rain flow method;
(c) calculate the equivalent stress width of cloth σ of this Simulating of Fatigue Stress Spectra according to Miner fatigue damage stress amplitude equivalence formula
i
(d) with equivalent stress amplitude σ
iThe computing formula of hardware fatigue surplus life is calculated in substitution:
Can obtain the fatigue surplus life of the crucial measuring point of crane structure.
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| CN103838931A (en) * | 2014-03-10 | 2014-06-04 | 太原科技大学 | Method for evaluating remanufacturing access period of engineering mechanical arm rest class structure |
| CN104537241A (en) * | 2014-12-30 | 2015-04-22 | 广西科技大学 | Wheel rim fatigue analysis method |
| CN105069266A (en) * | 2015-09-10 | 2015-11-18 | 福建省特种设备检验研究院 | Crane work device part service life evaluation method |
| CN105600682A (en) * | 2015-12-22 | 2016-05-25 | 江苏省特种设备安全监督检验研究院 | Crane strain monitoring method based on time-to-digital conversion technology |
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| CN110704979A (en) * | 2019-09-30 | 2020-01-17 | 三一海洋重工有限公司 | Crane life evaluation method and device and electronic equipment |
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| CN103838931A (en) * | 2014-03-10 | 2014-06-04 | 太原科技大学 | Method for evaluating remanufacturing access period of engineering mechanical arm rest class structure |
| CN103838931B (en) * | 2014-03-10 | 2017-08-29 | 太原科技大学 | A kind of engineering machinery arm support class formation remanufactures access phase appraisal procedure |
| CN104537241A (en) * | 2014-12-30 | 2015-04-22 | 广西科技大学 | Wheel rim fatigue analysis method |
| CN104537241B (en) * | 2014-12-30 | 2018-05-11 | 广西科技大学 | Wheel rim flange ring fatigue analysis method |
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| CN105600682A (en) * | 2015-12-22 | 2016-05-25 | 江苏省特种设备安全监督检验研究院 | Crane strain monitoring method based on time-to-digital conversion technology |
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| CN108304647A (en) * | 2018-01-30 | 2018-07-20 | 太原科技大学 | Ladle carne metal structure characteristics life appraisal procedure based on rail joint defect |
| CN108304647B (en) * | 2018-01-30 | 2021-04-09 | 太原科技大学 | Method for evaluating characteristic service life of metal structure of casting crane based on rail joint defects |
| CN108760371A (en) * | 2018-07-04 | 2018-11-06 | 南京泽楚科技有限公司 | A kind of in-service hoisting machinery structure residual life computational methods |
| CN110704979A (en) * | 2019-09-30 | 2020-01-17 | 三一海洋重工有限公司 | Crane life evaluation method and device and electronic equipment |
| CN110926770A (en) * | 2019-11-12 | 2020-03-27 | 上海宝钢工业技术服务有限公司 | Quantitative evaluation method for fatigue life of crane steel beam group |
| CN111985020A (en) * | 2020-04-17 | 2020-11-24 | 中建三局第一建设工程有限责任公司 | Calculation system and calculation method for walking and hoisting loads of truck crane |
| CN111985020B (en) * | 2020-04-17 | 2023-10-27 | 中建三局第一建设工程有限责任公司 | Automobile crane walking and lifting load calculating system and calculating method |
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