CN102730571B - Online monitoring and fault diagnosing system for crane - Google Patents

Online monitoring and fault diagnosing system for crane Download PDF

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CN102730571B
CN102730571B CN201210178781.4A CN201210178781A CN102730571B CN 102730571 B CN102730571 B CN 102730571B CN 201210178781 A CN201210178781 A CN 201210178781A CN 102730571 B CN102730571 B CN 102730571B
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subsystem
information
monitoring
hoisting crane
crane
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CN102730571A (en
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吴波
贾广飞
胡友民
谢锋云
程瑶
金超
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Huazhong University of Science and Technology
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Huazhong University of Science and Technology
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Abstract

The invention discloses an online and fault diagnosing system for a crane. The system comprises: a signal collection subsystem which is used for obtaining various state information in the crane operation process; a datum acquisition subsystem which is used for acquiring the information obtained by the signal collection subsystem, preprocessing the information and outputting the information; an online monitoring and alarming subsystem which is used for analyzing the information output by the datum acquisition subsystem, the online monitoring, and the fault alarming; a wireless communication subsystem which is used for positioning the crane and transmitting data input to the online monitoring and alarming subsystem; and a remote monitoring and diagnosing subsystem which is used receiving and analyzing the data transmitted by the wireless communication subsystem to realize online monitoring, fault alarming, fault diagnosing and trend analyzing in a remote manner. The system has the functions of online monitoring, advance warning and alarming, analyzing, diagnosing, wireless communication remote monitoring and the like, so reliable bases are provided for the safe operation of the crane, and safety accidents are avoided or reduced.

Description

A kind of hoisting crane on-line monitoring and fault localization system
Technical field
The present invention relates to monitoring and the area of maintenance of hoisting crane, specifically a kind of on-line monitoring of hoisting crane and fault localization system, be particularly useful for crane in bridge type, transfer crane and tower crane.
Background technology
Hoisting crane is a kind of for lifting by crane and transport the large-scale engineering machinery of weight, is usually used in building, bridge, metallurgy, harbour, electric power, petrochemical industry and automobile and other industries.By planform, can be divided into: crane in bridge type, transfer crane and tower crane etc.
Some hoisting cranes, in outdoor open work, experience hardships precipitation, and even overload operation, after long operation, there will be various faults unavoidably.The appearance of fault has not only affected the normal operation of hoisting crane, also likely causes safety misadventure, even causes heavy economic losses or personal casualty.In hoisting crane operational process, owing to breaking down, be not found in time to cause the report of safety misadventure of common occurrence.
As can be seen here, the safety inspection of hoisting crane operation and maintenance are very necessary.Common safety check means have maintenance and inspection afterwards and periodic inspection maintenance.These safety check means rely on the precision of detecting instrument and inspector's experience level to a great extent, be difficult to the operation conditions of hoisting crane to accomplish the early prediction of Real-Time Monitoring and fault, and utilize hoisting crane on-line monitoring and the fault localization system of sensing technology, the communication technology and computer technology exploitation to address this problem well.
In recent years, some units have developed many crane monitoring systems both at home and abroad.As portal crane metal construction on-line monitoring system, tower crane on-line monitoring system, container handling crane remote supervision system and the high pedestal jib crane Maintenance Decision Supporting System based on on-line monitoring etc.
Patent documentation 200420030955.3 discloses a kind of tower crane detector, and this monitor is comprised of weight sensor, dolly rang sensor, height under hook sensor, microprocessor, telltale and loudspeaker.This detector can measure the weight of hung article, highly, carry out voice prompt alarm automatic train stop, prevented the generation of operation error and accident.Patent documentation 201020658325.6 discloses a kind of crane load track data acquisition and recording device, and it comprises the electronic chip of pressure sensor, A/D conversion, data processing and data presentation device, real-time data acquisition and data storage.This device plays certain warning function to operating against regulations, the data management of production logistics is had to certain booster action simultaneously.Patent documentation 200910074260.2 discloses a kind of large-scale foundry crane monitoring and failure warning system, and it comprises sensor, data acquisition unit, signal process box, collection monitoring computer and computing machine related software, also disposes external memory.Can obtain the multi-source informations such as vibration, temperature, electric current, voltage and electric switch amount simultaneously, can carry out synchronous failure analysis and the comprehensive judgement of multi-parameter, be particularly suitable for the large-scale metallurgical hoisting crane that security level required is high.
Above monitoring system or only for the hoisting crane of certain type, do not have commonality, or only for some parameter index of hoisting crane, monitoring information is not comprehensive, or only has monitoring function, not diagnosis and forecast function etc.
Summary of the invention
The object of the invention is the problem for current existence, a kind of hoisting crane on-line monitoring and fault localization system are provided, the information of derricking gear, steel rope, speed reduction gearing, motor, beams of metal and wind speed etc. in this system energy on-line monitoring hoisting crane work process, there is on-line monitoring function, give warning in advance and warning function, analysis and diagnosis function and radio communication remote monitoring function, failure-free foundation can be provided for the safe operation of hoisting crane, avoid or reduce occurring safety misadventure.
A kind of hoisting crane on-line monitoring and the fault localization system of realizing the object of the invention comprise:
Picking up signal subsystem, for obtaining the status information of hoisting crane operational process, comprises weight, lifting altitude, lifting velocity, the state of steel rope, stress and the ambient wind velocity of the temperature of the vibration of reductor, motor, beams of metal key point of lift heavy;
Data acquisition subsystem, carries out pretreatment for the information that picking up signal subsystem is obtained, and it is gathered to output;
Field monitoring and warning subsystem, for the information of described data acquisition subsystem output is carried out to analyzing and processing, show and fault alarm to carry out the state of hoisting crane at operator's compartment;
Radio communication subsystem, its via satellite global position system GPS realize the coordinate setting of hoisting crane, and transmit the original data that gathers and through the characteristic data of field monitoring and warning subsystem processes by communication;
Remote monitoring and diagnosis subsystem, it is for receiving the data of radio communication subsystem transmission and data being carried out to analyzing and processing, with in long-range state demonstration, fault alarm, trouble diagnosing and the trend analysis of carrying out hoisting crane.
As improvement of the present invention, described remote monitoring and diagnosis subsystem comprises:
State display module, for showing the described status information of obtaining, to realize the on-line monitoring to equipment;
Alarm module, for the operation conditions of equipment being carried out to early warning and warning according to described status information, comprises audible alarm and color warning;
Analyzing and diagnosing module, the data analysis diagnosis for to receiving, comprises time-domain waveform analysis, spectral analysis, coherent analysis, trouble diagnosing, trend analysis and statistical graph analysis;
Data management module, for carrying out real-time storage, inquiry, deletion and backup to the data that receive and the result data of analyzing and diagnosing.
As improvement of the present invention, the status information of described hoisting crane is obtained by various sensors, wherein, the weight information of lift heavy obtains by weight sensor, lifting altitude is obtained by height sensor, lifting velocity obtains by increment grating encoder, the fracture of wire of steel rope obtains by leakage field sensor, the vibration of reductor is obtained by acceleration pick-up, the stress of beams of metal key point obtains by resistance strain gage, motor temperature obtains by resistance to heat, and ambient wind velocity obtains by air velocity transducer.
As improvement of the present invention, described data acquisition subsystem 2 comprises signal regulating device and data acquisition module, first the information that described picking up signal subsystem obtains carry out signal filtering and amplification by described signal regulating device, then, by described data acquisition module, gathers rear output.
As improvement of the present invention, described field monitoring and warning subsystem comprise state display module and alarm module, the described status information gathering shows by described state display module after processing by analysis, and carry out operation conditions early warning and warning by described alarm module, for realizing the on-the-spot on-line monitoring to equipment.
As improvement of the present invention, described remote monitoring and diagnosis subsystem is arranged on server, each terminal computer is by this server of access to netwoks, so that the result of state demonstration, fault alarm, trouble diagnosing and the trend analysis of the hoisting crane in described remote monitoring and diagnosis subsystem is presented on each terminal computer, realize remote monitoring and diagnosis.
Compared with prior art, beneficial effect of the present invention is embodied in: this system can be by wireless communication technology in long-range realization the on-line monitoring to crane job, and can realize and reporting to the police and trouble diagnosing, on-line monitoring, remote monitoring and general inspection and diagnosis and the performance predication function with multi-parameter have the access function based on Internet/Intranet simultaneously.
(1) native system has real time on-line monitoring function.Can monitor in real time the operation conditions of hoisting crane, show numerical information and the graphical information of operation conditions, there is early warning and warning function, be different from common periodic monitoring mode.
(2) native system can be monitored multi-source information, powerful.The weight, lifting altitude, lifting velocity, the fracture of wire of steel rope, the vibration of reductor, the stress of beams of metal key point, the information such as the temperature of motor and ambient wind velocity that comprise lift heavy.
(3) native system can be realized work-site and long-range monitoring simultaneously, adopts GPS/GPRS communication, realizes global location and data synchronous transmission.
(4) form of native system based on web realizes, and in long-range employing Browser/Server Mode (B/S pattern), can realize long-range multicomputer access, easy to maintenance.Not only can realize on-line monitoring, also there is trouble diagnosing and trend prediction function.
Accompanying drawing explanation
The overall structure of Fig. 1 system.
Fig. 2 picking up signal subsystem.
The specific embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is further illustrated.
Fig. 1 is monitoring in the present embodiment and the overall construction drawing of fault localization system, has described the informational linkage between native system and hoisting crane.
Native system comprises picking up signal subsystem 1, data acquisition subsystem 2, field monitoring and warning subsystem 3, radio communication subsystem 4 and remote monitoring and diagnosis subsystem 5 totally five parts.Picking up signal subsystem 1 obtains status signal from the different parts of hoisting crane; Output to data acquisition subsystem 2 and carry out pretreatment and the data acquisitions such as filtering, amplification; The data transmission gathering also stores field monitoring into and warning subsystem 3, carries out state demonstration and fault alarm; Then storing on-the-spot real time data into is transferred to remote monitoring and diagnosis subsystem 5 by radio communication subsystem 4 and carries out signal analysis, feature extraction, trouble diagnosing and trend prediction, terminal computer is by Internet/Intranet net, adopt the mode of browser/server to be connected with remote server, to realize access and operation.
Picking up signal subsystem 1 is for obtaining the status information of hoisting crane operational process, specifically comprise that the weight, lifting altitude, lifting velocity, the fracture of wire of steel rope, the vibration of reductor, the stress of beams of metal key point of lift heavy are, the information such as the temperature of motor and ambient wind velocity are shown in accompanying drawing 2.The weight information of lift heavy by weight sensor 11 obtain, lifting altitude by height sensor 12 obtain, lift heavy lifting velocity and position with increment grating encoder 13 obtain, the fracture of wire of steel rope by leakage field sensor 14 obtain, the vibration signal of reductor by acceleration pick-up 15 obtain, the stress of beams of metal key point by resistance strain gage 16 obtain, motor temperature obtains with ambient wind velocity and obtained by air velocity transducer 18 by resistance to heat 17.These sensors can suitably be chosen according to the particular type of hoisting crane and working environment, and the selection of Sensor can be determined according to the method for service experience or finite element analysis.
Data acquisition subsystem 2 carries out pretreatment for the information that picking up signal subsystem is exported, and pretreated information is carried out to data acquisition and storage.First by signal regulating device, carry out the pretreatments such as signal filtering and amplification, signal after pretreatment is divided into digital signal, becomes analog signal, gradual analog signal and switching value signal soon, select respectively corresponding capture card to gather, several capture cards and capture program form data acquisition module.Pretreated digital signal is directly by data collecting module collected, and analog quantity will be undertaken gathering after mould/number conversion by A/D capture card.Before data acquisition, in data acquisition program, need first to select collection card number, acquisition channel, sampling frequency and sampling length etc.
Field monitoring and warning subsystem 3 are, processing for further analysis to the information of data acquisition subsystem 2 outputs, to carry out state demonstration and fault alarm.This subsystem comprises state display module and alarm module from function.State display module, for showing lift heavy weight, lifting altitude, lifting velocity, the fracture of wire of steel rope, the temperature of motor and ambient wind velocity digital information and the graphical information of collection, is convenient to the on-line monitoring of chaufeur to equipment.Alarm module is for operation conditions early warning and warning to equipment.The function of this subsystem realizes by the embedded computer, read-out, buzzer phone and the corresponding computer software that are arranged in operator's compartment.
Radio communication subsystem 4 is to realize long-range arriving remote monitoring and diagnosis subsystem 5 to the coordinate setting of operation hoisting crane with the real-time Data Transmission of collection in worksite.Global position system GPS is realized the coordinate setting of hoisting crane via satellite, by cordless communication network (as GSM/GPRS), realizes data transmission.This function can complete by the GPS/GPRS module being connected with on-the-spot embedded computer.
Remote monitoring and diagnosis subsystem 5 is for receiving the data of radio communication subsystem 4 transmission and data being further analyzed and being processed, to carry out state demonstration, fault alarm, trouble diagnosing and trend analysis.This subsystem comprises state display module, alarm module, analyzing and diagnosing module, data management module and supplementary module from function.The function of this subsystem realizes by long-range server and terminal computer, adopts the mode construction of browser/server.Server is realized the function of www server and database server with a computing machine, functional software is arranged on server, and terminal computer is by Internet/Intranet access services device.
Wherein state display module is for showing lift heavy weight, lifting altitude, lifting velocity, the fracture of wire of steel rope, the characteristic quantity information of the vibration of reductor, the stress of beams of metal key point, the temperature of motor, ambient wind velocity and extraction of work-site, these information have numerical information and graphical information, the on-line monitoring for engineering staff to equipment;
Alarm module is for carrying out early warning and warning to the operation conditions of equipment.Have two kinds of sound alarm form and Show Color alarm forms, as lift heavy load reach rated load 90% time carry out sound early warning, reach rated load 100% time carry out audible alarm;
Analyzing and diagnosing module comprises that the real time data to gathering carries out time-domain waveform analysis and Time-domain Statistics amount and show (as average, variance, maxim), spectral analysis (as amplitude spectrum, power spectrum), autocorrelation analysis, trouble diagnosing, trend analysis and statistical graph (as monthly, season and year);
Data management module comprises real-time data memory and path query, and the functions such as the storage of characteristic data and historical data, inquiry, deletion and backup are supported keyword query and fuzzy query.Hoisting crane on-line monitoring of the present invention and fault localization system be---subsystem---module grading design according to system, during use, can select as the case may be corresponding module and increase new module, especially be applicable to the on-line monitoring to tower crane, transfer crane or crane in bridge type, there is certain commonality, can carry out scene and remote online monitoring to hoisting crane simultaneously.

Claims (2)

1. hoisting crane on-line monitoring and a fault localization system, comprising:
Picking up signal subsystem (1), for obtaining the status information of hoisting crane operational process, comprises weight, lifting altitude, lifting velocity, the state of steel rope, the temperature of the vibration of reductor, motor, the stress of beams of metal and the ambient wind velocity of lift heavy;
Data acquisition subsystem (2), carries out pretreatment for the information that described picking up signal subsystem is obtained, and to pretreated information and storage;
Field monitoring and warning subsystem (3), for the information of described data acquisition subsystem collection is carried out to analyzing and processing, show and fault alarm to carry out the state of hoisting crane at operation field;
Radio communication subsystem (4), its via satellite global positioning system realize the coordinate setting of hoisting crane, and by cordless communication network, the information remote of described collection is exported;
Remote monitoring and diagnosis subsystem (5), the data of its long-range reception radio communication subsystem transmission are also carried out analyzing and processing to data, in long-range state demonstration, fault alarm, trouble diagnosing and the trend analysis of carrying out hoisting crane;
Wherein, described remote monitoring and diagnosis subsystem (5) comprising:
State display module, for showing obtained described status information, to realize the on-line monitoring to equipment;
Alarm module, for the operation conditions of equipment being carried out to early warning and warning according to described status information, wherein reporting to the police can be audible alarm or color warning;
Analyzing and diagnosing module, the data analysis diagnosis for to receiving, specifically comprises time-domain waveform analysis, spectral analysis, coherent analysis, trouble diagnosing, trend analysis and statistical graph analysis;
Data management module, the data of receiving for achieving a butt joint and the result data of analyzing and diagnosing carry out real-time storage, inquiry, deletion and backup;
Described picking up signal subsystem (1) comprising: weight sensor (11), for obtaining the weight information of described lift heavy; Height sensor (12), for obtaining described lifting altitude information; Increment grating encoder (13), for obtaining described lifting velocity information; Leakage field sensor (14), for obtaining the status information of described steel rope; Acceleration pick-up (15), for obtaining the vibration information of described reductor; Resistance strain gage (16), for obtaining the stress information of described beams of metal; Resistance to heat (17), for obtaining the temperature information of described motor; And air velocity transducer (18), for obtaining described ambient wind velocity information;
Described remote monitoring and diagnosis subsystem (5) is arranged on server, each terminal is by this server of access to netwoks, so that the result of state demonstration, fault alarm, trouble diagnosing and the trend analysis of the hoisting crane in described remote monitoring and diagnosis subsystem (5) is transferred in each terminal, realize remote monitoring and diagnosis;
Described field monitoring and warning subsystem (3) comprise state display module and alarm module, the described status information gathering shows by described state display module after processing by analysis, wherein, above-mentioned state display module is used for showing lift heavy weight, lifting altitude, lifting velocity, the fracture of wire of steel rope, the vibration of reductor, the stress of beams of metal key point, the temperature of motor, the characteristic quantity information of ambient wind velocity and extraction, above-mentioned information comprises numerical information and graphical information, and carry out operation conditions early warning and warning by described alarm module, wherein alarm message comprises that audible alarm and Show Color report to the police two kinds, to realize the on-the-spot on-line monitoring to equipment.
2. a kind of hoisting crane on-line monitoring according to claim 1 and fault localization system, it is characterized in that, described data acquisition subsystem (2) comprises signal regulating device and data acquisition module, first the status information that described picking up signal subsystem (1) obtains carries out pretreatment by this signal regulating device, comprise signal filtering and amplification, then by described data acquisition module, carry out data acquisition storage.
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Cited By (2)

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Publication number Priority date Publication date Assignee Title
CN109720814A (en) * 2019-01-08 2019-05-07 四川省自贡运输机械集团股份有限公司 A kind of belt conveyor remote failure monitoring and fault diagnosis system
CN109720814B (en) * 2019-01-08 2020-11-24 四川省自贡运输机械集团股份有限公司 Remote fault monitoring and diagnosing system for belt conveyor

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