CN104760892A - Harbor crane health monitoring and forecasting visualization system - Google Patents
Harbor crane health monitoring and forecasting visualization system Download PDFInfo
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- CN104760892A CN104760892A CN201410005025.0A CN201410005025A CN104760892A CN 104760892 A CN104760892 A CN 104760892A CN 201410005025 A CN201410005025 A CN 201410005025A CN 104760892 A CN104760892 A CN 104760892A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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Abstract
The invention provides a harbor crane health monitoring and forecasting visualization system including a sensor subsystem, an information collection and transmission subsystem, a central server and a system client; the sensor subsystem is used for acquiring real-time operation parameters of a crane; the information collection and transmission subsystem is used for sending the real-time operation parameters of the crane to the central server through a wireless sending unit; the central server is used for storing and managing the real-time operation parameters of the crane, then performing health diagnosis on the crane to obtain a health condition diagnosis report, also forecasting whether the crane is failed or goes wrong according to the diagnosis result, and evaluating the operation safety of the crane to obtain a safety evaluation report; the system client is used for displaying the real-time operation parameters of the crane, the health condition diagnosis report and the safety evaluation report. The system can comprehensively, efficiently and real-timely monitor the harbor crane health condition, so as to ensure the safety operation of the harbor crane.
Description
Technical field
The invention belongs to health monitoring of equipment technical field, be specifically related to a kind of portal crane health monitoring and forecast visualization system.
Background technology
Along with the development of national economy and the raising of production complexity, portal crane plays an important role in port and pier transport, portal crane is gradually towards the future development of maximization, function diversification, and the requirement of government and society to portal crane management of safe operation is also more and more higher.
At present, portal crane safety management level also rests on reduced levels, main manifestations is the following aspects: 1) safety control aspect, still based on regular inspection, prison inspection, the technological means adopted mostly is the range estimation, the sense organ that relatively fall behind and judges, shuts down measurement, magnetic particle inspection etc., the work capacity of inspector is large but efficiency is lower, and the testing result under stopped status can not illustrate the running condition under mode of operation; 2) security monitoring of portal crane and management automation level low, still mainly rely on the traditional approach such as daily artificial spot check and periodical maintenance, have that efficiency is low, poor real, information not comprehensively, be not easy to the problem such as statistics and analysis of data; 3) existing portal crane monitored control system function singleness, cannot grasp hoisting crane operational factor in real time, all sidedly, therefore, is difficult to carry out comprehensive effective monitoring to hoisting crane, and then is difficult to ensure field man safety.
Summary of the invention
For the defect that prior art exists, the invention provides a kind of portal crane health monitoring and forecast visualization system, monitoring portal crane state of health that can be comprehensive, efficient, real-time, ensures the safe operation of portal crane.
The technical solution used in the present invention is as follows:
The invention provides a kind of portal crane health monitoring and forecast visualization system, comprising: sensor subsystem, information acquisition and transmission subsystem, central server and system client;
Described sensor subsystem is for obtaining hoisting crane real time execution parameter;
The described hoisting crane real time execution parameter that described information acquisition and transmission subsystem get for gathering described sensor subsystem, and by wireless transmission unit, described hoisting crane real time execution parameter is sent to described central server;
Described central server is for receiving the hoisting crane real time execution parameter from described information acquisition and transmission subsystem, storage and management is carried out to described hoisting crane real time execution parameter, and then Gernral Check-up is carried out to described hoisting crane, obtain health status diagnosis report; And predict whether described hoisting crane lost efficacy or et out of order according to diagnostic result, evaluate described hoisting crane safety in operation, obtain safety evaluation report;
Described system client is for showing described hoisting crane real time execution parameter, the report of described health status diagnosis and described safety evaluation report.
Preferably, described sensor subsystem comprises:
First kind sensor, for monitoring Mechanism of crane state of health;
Equations of The Second Kind sensor, for monitoring crane structure state of health;
Electric control system, for monitoring the electric state of health of hoisting crane;
Intelligent label, is installed on the crucial spot check position of hoisting crane, for identifying the crucial spot check position of hoisting crane.
Preferably, described first kind sensor involving vibrations sensor, temperature sensor and displacement pickup; Described vibration sensor hoist for gathering/luffing/swing type mechanism drive motor, hoist/the vibration signal of luffing/swing type mechanism reductor; Described temperature sensor hoists for gathering/temperature signal of luffing/swing type mechanism reductor; Institute's displacement sensors hoists for gathering/displacement signal of luffing/slewing gear brake;
Described Equations of The Second Kind sensor comprises strain sensor, for gathering portal gantry shelf structure, upload post, principal arm frame large arm, otic placode hinged place and otic placode root strain signal.
Preferably, described vibration sensor is piezoelectric acceleration transducer, hole knockout, welding manner or magnetic pedestal mode is adopted to be installed on drive motor in each mechanism of portal crane and reductor, for the vibration acceleration change information of awareness driven motor and reductor; The installation site of described vibration sensor comprises: the driving main motor output shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism; X, Y, Z-direction outside X, Y, Z-direction, slow-speed shaft outside the reductor high speed shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described temperature sensor is high heat conduction packaged type thermocouple, adopts thread connecting mode to be installed on the reductor in each mechanism of portal crane, for the temperature information of perception each mechanism reductor lubricating oil; The installation site of described temperature sensor comprises: the reductor slow-speed shaft oil sealing hole of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Institute's displacement sensors is high precision linear type displacement sensor, adopts bolt fixed mode to be installed on the drg in each mechanism of portal crane, for the displacement information of perception brake block; The installation site of institute's displacement sensors comprises: on the brake block of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described strain sensor is from temperature compensation fiber Bragg grating strain sensor, adopts welding manner to be installed on steel structure; Concrete installation site is: on the web of described girder/auxiliary girder/end carriage or cover plate traveling mechanism of the larger traveller/wheeling mechanism wheel on the movable pulley of lifting mechanism or fixed pulley;
Described intelligent label adopts high-frequency RF ID radio-frequency card, adopts mounting means of pasting or punch to be installed on the crucial spot check position of hoisting crane, for numbering accordingly crucial spot check position.
Preferably, described information acquisition and transmission subsystem comprise: vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit, electrical control signal collecting unit, intelligent spot check terminal and the information transmission system; The described information transmission system is connected with described vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit, intelligent spot check terminal and the described information transmission system respectively;
Wherein, described vibration signals collecting unit, described temperature signal collection unit, described displacement signal acquisition unit and described strain signal collecting unit gather the vibration of respective sensor, temperature, displacement and strain signal respectively, and upload to described central server by the described information transmission system;
Described intelligent spot check terminal built-in has rfid interrogator, for reading the number information of described smart tag memory storage, and directly uploads to described central server by wireless transmission unit;
Described electrical control signal collecting unit for gathering the electric signal of electric control system, and uploads to described central server by the described information transmission system.
Preferably, the described information transmission system comprises: data buffering queue, data server, Redis server and monitor client;
Described data buffering queue, as the data relay server between each sensor and data server, be responsible for cushioning the monitoring data collected from each sensor of hoisting crane, and these monitoring data data is sent to data server by timing;
Described data server comprises data receiver, data parser and data providing end; Described data receiver provides data decryptor port, the monitoring data that the transmit port for monitored data buffer queue sends, and utilizes data parser to resolve monitoring data, by the data after parsing stored in described Redis server; Described data providing end as Web server for monitor client provides service; When monitor client sends monitoring data request to described data server, described data providing end is read monitoring data from Redis server and is responsively turned back to described monitor client.
Preferably, described central server comprises: safety archive administration module, intelligent spot check module, mechanism's health monitoring module, monitoring structural health conditions module, electrically health monitoring module, Gernral Check-up forecast module and safety evaluatio module;
Described safety archive administration module: for display and management maintenance port crane safety method archives, and provide user to input and management interface; Inputted and management interface by described user, receive port crane safety method archives, by described system client inquiry, show and safeguard described port crane safety method archives; Wherein, described port crane safety method archives comprise the electronic drawing of portal crane, basic specification information table and great maintenance and renovation recorded information;
Described intelligent spot check module: for showing the intelligent inspection information of port crane key position, and provide user to input and management interface;
Described mechanism health monitoring module: for showing the Real-Time Monitoring information of port crane each mechanism operation conditions, and early warning and warning are carried out to failure mechanisms;
Described monitoring structural health conditions module: for showing the Real-Time Monitoring information of each constructional aspect of port crane, and early warning and warning are carried out to structural failure;
Described electric health monitoring module: for showing the Real-Time Monitoring information of port crane electric control system operation conditions, and early warning and warning are carried out to electrical malfunction;
Described Gernral Check-up forecast module: for showing the diagnosis report of each mechanism of port crane, structure, electric control system, and the Gernral Check-up report that port crane complete machine is overall;
Described safety evaluatio module: for showing the safety evaluation result of each mechanism of port crane, structure, electric control system, and the safety evaluation result that complete machine is overall.
Preferably, described central server structure MYSQL database cluster, redis data-base cluster and MongoDB data-base cluster; By described MYSQL database cluster, distributed storage original data and analysis result data; By described redis data-base cluster, distributed storage real time data; By described MongoDB data-base cluster, distributed storage document data.
Beneficial effect of the present invention is as follows:
Portal crane health monitoring provided by the invention and forecast visualization system, with the sensing technology of advanced person, intelligence repair and maintenance management technique, based on monitoring and prediction technology and Safety Evaluation Technology, combine Internet of Things, cloud platform, the advanced information techenology such as large data mining, the efficiency overcoming traditional portal crane management of safe operation existence is low, poor real, monitor message is not comprehensive, the problems such as monitoring function is single, achieve diagnosis and the Function of Evaluation of the healthy operation conditions of portal crane simultaneously, the generation of hoisting crane mechanical breakdown and safety misadventure can be forecast in time, for the safe operation ensureing portal crane, promote the safety management level of portal crane, improve port enterprise economic benefit etc. to have great importance.
Accompanying drawing explanation
Fig. 1 is portal crane health monitoring provided by the invention and the integral structure schematic diagram of forecast visualization system;
Fig. 2 is the diagram of circuit of information transmission system data handling procedure provided by the invention;
Fig. 3 is the data storage shelves composition of central server provided by the invention structure.
Detailed description of the invention
Below in conjunction with accompanying drawing, the present invention is described in detail:
The invention provides a kind of portal crane health monitoring and forecast visualization system, mainly Real-Time Monitoring, Gernral Check-up, healthy forecast and health control etc. are carried out to the health status of port crane.Concrete, comprise: sensor subsystem, information acquisition and transmission subsystem, central server and system client four part, implementation structure health monitoring, mechanism's health monitoring and electrically health monitoring, and diagnose based on the health status of monitored data to portal crane, its safety is evaluated.As shown in Figure 1, be portal crane health monitoring and the integral structure schematic diagram of forecast visualization system, below describe in detail:
(1) sensor subsystem
Sensor subsystem, for obtaining hoisting crane real time execution parameter, comprising: first kind sensor, for monitoring Mechanism of crane state of health; Equations of The Second Kind sensor, for monitoring crane structure state of health; Electric control system, for monitoring the electric state of health of hoisting crane; Intelligent label, is installed on the crucial spot check position of hoisting crane, for identifying the crucial spot check position of hoisting crane.
Wherein, first kind sensor involving vibrations sensor, temperature sensor and displacement pickup; Described vibration sensor hoist for gathering/luffing/swing type mechanism drive motor, hoist/the vibration signal of luffing/swing type mechanism reductor; Described temperature sensor hoists for gathering/temperature signal of luffing/swing type mechanism reductor; Institute's displacement sensors hoists for gathering/displacement signal of luffing/slewing gear brake;
Equations of The Second Kind sensor comprises strain sensor, for gathering portal gantry shelf structure, upload post, principal arm frame large arm, otic placode hinged place and otic placode root strain signal.
In addition, in practical application, vibration sensor is piezoelectric acceleration transducer, adopts hole knockout, welding manner or magnetic pedestal mode to be installed on drive motor in each mechanism of portal crane and reductor, for the vibration acceleration change information of awareness driven motor and reductor; The installation site of described vibration sensor includes but not limited to: the driving main motor output shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism; X, Y, Z-direction outside X, Y, Z-direction, slow-speed shaft outside the reductor high speed shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Temperature sensor is high heat conduction packaged type thermocouple, adopts thread connecting mode to be installed on the reductor in each mechanism of portal crane, for the temperature information of perception each mechanism reductor lubricating oil; The installation site of described temperature sensor includes but not limited to: the reductor slow-speed shaft oil sealing hole of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Displacement pickup is high precision linear type displacement sensor, adopts bolt fixed mode to be installed on the drg in each mechanism of portal crane, for the displacement information of perception brake block, as operating state, travel displacement; The installation site of institute's displacement sensors includes but not limited to: on the brake block of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described strain sensor is from temperature compensation fiber Bragg grating strain sensor, adopts welding manner to be installed on steel structure; Installation site includes but not limited to: on the web of described girder/auxiliary girder/end carriage or cover plate traveling mechanism of the larger traveller/wheeling mechanism wheel on the movable pulley of lifting mechanism or fixed pulley;
Intelligent label adopts high-frequency RF ID radio-frequency card, adopts mounting means of pasting or punch to be installed on hoisting crane day-to-day operation and to need the position of spot check in safeguarding, for numbering accordingly so that identify spot check position.
(2) information acquisition and transmission subsystem
Information acquisition and transmission subsystem are used for the hoisting crane real time execution parameter that pick-up transducers subsystem gets, and by wireless transmission unit, hoisting crane real time execution parameter are sent to central server.
Information acquisition and transmission subsystem comprise: vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit, electrical control signal collecting unit, intelligent spot check terminal and the information transmission system; The described information transmission system is connected with described vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit, intelligent spot check terminal respectively; Wherein, vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit and strain signal collecting unit gather the vibration of respective sensor, temperature, displacement and strain signal respectively, and upload to described central server by the described information transmission system; Intelligence spot check terminal built-in has rfid interrogator, for reading the number information of described smart tag memory storage, and directly uploads to described central server by wireless transmission unit.
Basic specification and the technical index of each collecting unit are as follows:
(1) vibration signals collecting cell parameters:
| Project | Parameter |
| Port number: | 4～16CH |
| Input: | Preposition conditioner |
| Channel bandwidth: | 0～100KHz |
| A/D resolution: | 16bit |
| Signal to noise ratio: | ≥72dB |
| Data transfer mode: | USB |
| Sampling frequency: | Continuous acquisition 100KSPS/CH, stepping is optional |
| Anti-aliasing protection: | ≥100dB |
| Sampling length: | Mass memory (depending on hard disc of computer space size) |
| Triggering mode: | Single channel internal trigger |
| Analog input voltage scope: | ±5VP |
| Working temperature range: | -40°C-120℃ |
(2) temperature signal collection cell parameters:
| Project | Parameter |
| Probe mode: | High heat conduction packaging body |
| Port number: | 4 thermocouple passages |
| Sensor type: | K, T, J, E type |
| Resolution: | 0.04℃ |
| Precision: | max.+/-0.1%v.M.+0.3℃ |
| Sampling frequency: | 0～40Hz |
| Power consumption: | 60mW typical case |
| Working temperature range: | -20℃～85℃ |
(3) position signal acquisition cell parameters:
| Measurement range: | 0-10cm (customizable) |
| Resolution: | 0.1mm |
| Frequency acquisition: | 10K (can arrange) |
| Number of channels: | 6 passages |
| Temperature: | -60-+150℃ |
| Maximum operating speed: | 10m/s |
| Coefficient of impact: | IEC68-2-29:196850g |
| Oscillating Coefficients: | IEC68-2-6:198220g |
| Repeatability error: | ≤0.005mm |
| Linear precision error: | ≤0.05％ |
| Temperature factor: | ＜1.5ppm/℃ |
| Other performances | Dustproof and waterproof is grease proofing shockproof |
(4) strain signal collecting unit parameter:
Strain signal collecting unit adopts the GTS-ASHM-001 health monitoring (FBG) demodulator of independent research, be applicable to polytype fiber-optic grating sensor signal receiving and the sensing data dynamic acquisition such as optical fiber grating temperature, strain, pressure, displacement, also can be used for high speed signal demodulation and the data acquisition of optical fiber acceleration transducer.This health monitoring (FBG) demodulator adopts scan laser and parallel spectrum Detection Techniques, source device output optical power degree of utilization is up to more than 85%, compare traditional ASE+ adjustable filter technology, light source output power improves more than 100 times, power supply power consumption then declines 50%, and light source useful service life improves more than 10 years.Wherein, main performance index is as shown in the table.
(5) intelligent spot check terminal parameter:
(3) central server
Central server, for receiving the hoisting crane real time execution parameter from described information acquisition and transmission subsystem, carries out storage and management to described hoisting crane real time execution parameter, and then carries out Gernral Check-up to described hoisting crane, obtains health status diagnosis report; And predict whether described hoisting crane lost efficacy or et out of order according to diagnostic result, evaluate described hoisting crane safety in operation, obtain safety evaluation report.
Concrete, central server comprises: safety archive administration module, intelligent spot check module, mechanism's health monitoring module, monitoring structural health conditions module, electrically health monitoring module, Gernral Check-up forecast module and safety evaluatio module;
Safety archive administration module: for display and management maintenance port crane safety method archives, and provide user to input and management interface; Inputted and management interface by described user, receive port crane safety method archives, by described system client inquiry, show and safeguard described port crane safety method archives; Wherein, described port crane safety method archives comprise the electronic drawing of portal crane, basic specification information table and great maintenance and renovation recorded information; By safety archive administration module, be convenient to carry out unified management, information sharing to portal crane safety method document, can be the parts replacement of portal crane simultaneously, failure analysis, health assessment provide effective reference.
Intelligence spot check module: for showing the intelligent inspection information of port crane key position, and provide user to input and management interface; By intelligent spot check module, information techenology and handheld mobile device is used to achieve the spot check standardization of port crane daily repair and maintenance spot check project, simple operation, data effectuation, record is with no paper, supervise scientific, information sharing, can the use safety of significantly lift crane tool applying unit level of management and equipment;
Mechanism's health monitoring module: for showing the Real-Time Monitoring information of port crane each mechanism operation conditions, and point out user to contingent failure mechanisms in sound and light alarm mode.By mechanism's health monitoring module, can the operation conditions of each mechanism of Real-Time Monitoring portal crane, can early warning in time to contingent failure mechanisms, to minimizing economic loss, reduction safety misadventure is significant;
Monitoring structural health conditions module: for showing the Real-Time Monitoring information of each constructional aspect of port crane, and point out user to contingent physical construction inefficacy in sound and light alarm mode.By monitoring structural health conditions module, can Real-Time Monitoring portal crane each constructional aspect, losing efficacy to contingent physical construction can early warning in time, and to minimizing economic loss, reduction safety misadventure is significant;
Electric health monitoring module: for showing the Real-Time Monitoring information of port crane electric control system operation conditions, and point out user to contingent electrical malfunction in sound and light alarm mode.By electric health monitoring module, can the operation conditions of Real-Time Monitoring portal crane electric control system, can early warning in time to contingent electrical accident, to minimizing economic loss, reduction safety misadventure is significant;
Gernral Check-up forecast module: for showing the diagnosis report of each mechanism of port crane, structure, electric control system, and the Gernral Check-up report that port crane complete machine is overall; By Gernral Check-up forecast module, can the health status of each mechanism of hoisting crane, structure, electric system be passed judgment on, be diagnosed, thus the holistic health of hoisting crane can be grasped accurately and real-time, the prevention for the economic loss avoiding sudden shutdown to cause and safety misadventure is significant;
Safety evaluatio module: for showing the safety evaluation result of each mechanism of port crane, structure, electric control system, and the safety evaluation result that complete machine is overall.Take the strategy by analytical hierarchy process and fuzzy comprehensive evaluation method reasonable combination, the advantage giving full play to the two makes up the other side's deficiency, more reasonably can realize the objective appraisal for this substantial equipment of portal crane.
(4) system client
System client be used for hoisting crane real time execution parameter, health status diagnosis report, safety evaluation report, and predicting residual useful life report display translation and management function.
Portal crane health monitoring provided by the invention and forecast visualization system, specific works flow process comprises following step:
Step 1: obtain hoisting crane health information
Hoisting crane health information is obtained by following components: collect safety method archive information, collection key position inspection information, collecting mechanism operation information, gather constructional aspect information, gather electric control system operation information.Wherein the specific implementation method of each several part acquisition of information is:
The collection of safety method archive information: by the electronic drawing of portal crane, basic specification information table and great maintenance and renovation record etc., directly by system software typing central server.
The collection of key position inspection information: utilize intelligent spot check terminal scanning to be installed on intelligent label on hoisting crane, reading area information and spot check project, spot check result uploads to central server by wired or wireless mode and stores.
The collection of mechanism's operation information: by installing corresponding sensor and signal gathering unit on the lifting mechanism of hoisting crane, luffing mechanism, rotating mechanism and traveling gear, obtain the health information of each mechanism of hoisting crane.Wherein, employing vibration sensor, temperature sensor obtain vibration, the bearing temperature information of drive motor, reductor in each mechanism, adopt position transduser to obtain brake block stroke and the status information of each gear brake.
The collection of constructional aspect information: by hoisting crane door frame, rotating disk, upload on the steel structures such as post, balanced system, principal arm frame and corresponding sensor be installed, gather the real time status information of hoisting crane each main steel structure.Wherein, adopt strain sensor to obtain distortion, the strain information of weld seam between each main steel structure of hoisting crane and steel structure, adopt calibrate AE sensor to obtain the Crack Damage information of each main steel structure of hoisting crane.
The collection of electrical system information: by directly reading the control signal of electric control system PLC on hoisting crane, obtains the real-time traffic information of hoisting crane electric system.
Step 2: the transmission of hoisting crane health information, storage.
The health information of each mechanism of the hoisting crane obtained, structure, electric system all transfers to central server by wireless sending module and stores, and the key position inspection information obtained directly is sent to central server by intelligent spot check terminal through wired or wireless mode and stores.Wherein, intelligent spot check terminal can be Intelligent handhold instrument.Transmission and the storage scheme of information are respectively:
Information transmission scheme:
As shown in Figure 2, information transmission system data handling procedure is:
The information transmission system comprises: data buffering queue, data server, Redis server and monitor client four part; Wherein, Redis server is that a use ANSI C language of increasing income is write, network enabled, can also can log type, the Key-Value data bank of persistence based on internal memory, data buffering queue is as the data relay server between each sensor and data server, be responsible for cushioning the monitoring data collected from each sensor of hoisting crane, and this monitoring data is sent to data server by timing;
Described data server comprises data receiver, data parser and data providing end; Described data receiver provides data decryptor port, the monitoring data that the transmit port for monitored data buffer queue sends, and utilizes data parser to resolve monitoring data, by the data after parsing stored in described Redis server; Described data providing end as Web server for monitor client provides service; When monitor client sends monitoring data request to described data server, described data providing end is read monitoring data from Redis server and is responsively turned back to described monitor client.
The scheme that information stores is:
In the present invention, the data storage shelves structure of central server structure as shown in Figure 3, comprises MYSQL(Relational DBMS) data-base cluster, redis data-base cluster and MongoDB(distribution type file stored data base) data-base cluster; By described MYSQL database cluster, the original data that distributed storage user frequency of utilization is higher and analysis result data; By described redis data-base cluster, distributed storage real time data; By described MongoDB data-base cluster, distributed storage document data, thus the throughput rate of support system in data, services and storage efficiency.
Step 3: the diagnosis of hoisting crane health status, evaluate and forecast.
After central server obtains the health information of hoisting crane, first signal processing method is utilized, mode identification method carries out pretreatment to obtained information and fault signature extracts, then integrated use Damage Failure Analysis method, Fault Tree Analysis, method for evaluating reliability, analytical hierarchy process and fuzzy comprehensive evaluation method, portal crane is carried out to the diagnosis of health status, the forecast of inefficacy or fault, and the evaluation of safety, the real time data of portal crane operation conditions is demonstrated finally by system client, Gernral Check-up is reported, safety evaluation report.
In sum, portal crane health monitoring provided by the invention and forecast visualization system, with the sensing technology of advanced person, intelligence repair and maintenance management technique, based on monitoring and prediction technology and Safety Evaluation Technology, combine Internet of Things, cloud platform, the advanced information techenology such as large data mining, the efficiency overcoming traditional portal crane management of safe operation existence is low, poor real, monitor message is not comprehensive, the problems such as monitoring function is single, achieve diagnosis and the Function of Evaluation of the healthy operation conditions of portal crane simultaneously, the generation of hoisting crane mechanical breakdown and safety misadventure can be forecast in time, for the safe operation ensureing portal crane, promote the safety management level of portal crane, improve port enterprise economic benefit etc. to have great importance.
The above is only the preferred embodiment of the present invention; it should be pointed out that for those skilled in the art, under the premise without departing from the principles of the invention; can also make some improvements and modifications, these improvements and modifications also should look protection scope of the present invention.
Claims (8)
1. portal crane health monitoring and a forecast visualization system, is characterized in that, comprising: sensor subsystem, information acquisition and transmission subsystem, central server and system client;
Described sensor subsystem is for obtaining hoisting crane real time execution parameter;
The described hoisting crane real time execution parameter that described information acquisition and transmission subsystem get for gathering described sensor subsystem, and by wireless transmission unit, described hoisting crane real time execution parameter is sent to described central server;
Described central server is for receiving the hoisting crane real time execution parameter from described information acquisition and transmission subsystem, storage and management is carried out to described hoisting crane real time execution parameter, and then Gernral Check-up is carried out to described hoisting crane, obtain health status diagnosis report; And predict whether described hoisting crane lost efficacy or et out of order according to diagnostic result, evaluate described hoisting crane safety in operation, obtain safety evaluation report;
Described system client is for showing described hoisting crane real time execution parameter, the report of described health status diagnosis and described safety evaluation report.
2. portal crane health monitoring according to claim 1 and forecast visualization system, it is characterized in that, described sensor subsystem comprises:
First kind sensor, for monitoring Mechanism of crane state of health;
Equations of The Second Kind sensor, for monitoring crane structure state of health;
Electric control system, for monitoring the electric state of health of hoisting crane;
Intelligent label, is installed on the crucial spot check position of hoisting crane, for identifying the crucial spot check position of hoisting crane.
3. portal crane health monitoring according to claim 2 and forecast visualization system, is characterized in that, described first kind sensor involving vibrations sensor, temperature sensor and displacement pickup; Described vibration sensor hoist for gathering/luffing/swing type mechanism drive motor, hoist/the vibration signal of luffing/swing type mechanism reductor; Described temperature sensor hoists for gathering/temperature signal of luffing/swing type mechanism reductor; Institute's displacement sensors hoists for gathering/displacement signal of luffing/slewing gear brake;
Described Equations of The Second Kind sensor comprises strain sensor, for gathering portal gantry shelf structure, upload post, principal arm frame large arm, otic placode hinged place and otic placode root strain signal.
4. portal crane health monitoring according to claim 3 and forecast visualization system, it is characterized in that, described vibration sensor is piezoelectric acceleration transducer, hole knockout, welding manner or magnetic pedestal mode is adopted to be installed on drive motor in each mechanism of portal crane and reductor, for the vibration acceleration change information of awareness driven motor and reductor; The installation site of described vibration sensor comprises: the driving main motor output shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism; X, Y, Z-direction outside X, Y, Z-direction, slow-speed shaft outside the reductor high speed shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described temperature sensor is high heat conduction packaged type thermocouple, adopts thread connecting mode to be installed on the reductor in each mechanism of portal crane, for the temperature information of perception each mechanism reductor lubricating oil; The installation site of described temperature sensor comprises: the reductor slow-speed shaft oil sealing hole of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Institute's displacement sensors is high precision linear type displacement sensor, adopts bolt fixed mode to be installed on the drg in each mechanism of portal crane, for the displacement information of perception brake block; The installation site of institute's displacement sensors comprises: on the brake block of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described strain sensor is from temperature compensation fiber Bragg grating strain sensor, adopts welding manner to be installed on steel structure; Concrete installation site is: on the web of described girder/auxiliary girder/end carriage or cover plate traveling mechanism of the larger traveller/wheeling mechanism wheel on the movable pulley of lifting mechanism or fixed pulley;
Described intelligent label adopts high-frequency RF ID radio-frequency card, adopts mounting means of pasting or punch to be installed on the crucial spot check position of hoisting crane, for numbering accordingly crucial spot check position.
5. portal crane health monitoring according to claim 4 and forecast visualization system, it is characterized in that, described information acquisition and transmission subsystem comprise: vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit, electrical control signal collecting unit, intelligent spot check terminal and the information transmission system; The described information transmission system is connected with described vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit, intelligent spot check terminal and the described information transmission system respectively;
Wherein, described vibration signals collecting unit, described temperature signal collection unit, described displacement signal acquisition unit and described strain signal collecting unit gather the vibration of respective sensor, temperature, displacement and strain signal respectively, and upload to described central server by the described information transmission system;
Described intelligent spot check terminal built-in has rfid interrogator, for reading the number information of described smart tag memory storage, and directly uploads to described central server by wireless transmission unit;
Described electrical control signal collecting unit for gathering the electric signal of electric control system, and uploads to described central server by the described information transmission system.
6. portal crane health monitoring according to claim 5 and forecast visualization system, it is characterized in that, the described information transmission system comprises: data buffering queue, data server, Redis server and monitor client;
Described data buffering queue, as the data relay server between each sensor and data server, be responsible for cushioning the monitoring data collected from each sensor of hoisting crane, and these monitoring data data is sent to data server by timing;
Described data server comprises data receiver, data parser and data providing end; Described data receiver provides data decryptor port, the monitoring data that the transmit port for monitored data buffer queue sends, and utilizes data parser to resolve monitoring data, by the data after parsing stored in described Redis server; Described data providing end as Web server for monitor client provides service; When monitor client sends monitoring data request to described data server, described data providing end is read monitoring data from Redis server and is responsively turned back to described monitor client.
7. portal crane health monitoring according to claim 1 and forecast visualization system, it is characterized in that, described central server comprises: safety archive administration module, intelligent spot check module, mechanism's health monitoring module, monitoring structural health conditions module, electrically health monitoring module, Gernral Check-up forecast module and safety evaluatio module;
Described safety archive administration module: for display and management maintenance port crane safety method archives, and provide user to input and management interface; Inputted and management interface by described user, receive port crane safety method archives, by described system client inquiry, show and safeguard described port crane safety method archives; Wherein, described port crane safety method archives comprise the electronic drawing of portal crane, basic specification information table and great maintenance and renovation recorded information;
Described intelligent spot check module: for showing the intelligent inspection information of port crane key position, and provide user to input and management interface;
Described mechanism health monitoring module: for showing the Real-Time Monitoring information of port crane each mechanism operation conditions, and early warning and warning are carried out to failure mechanisms;
Described monitoring structural health conditions module: for showing the Real-Time Monitoring information of each constructional aspect of port crane, and early warning and warning are carried out to structural failure;
Described electric health monitoring module: for showing the Real-Time Monitoring information of port crane electric control system operation conditions, and early warning and warning are carried out to electrical malfunction;
Described Gernral Check-up forecast module: for showing the diagnosis report of each mechanism of port crane, structure, electric control system, and the Gernral Check-up report that port crane complete machine is overall;
Described safety evaluatio module: for showing the safety evaluation result of each mechanism of port crane, structure, electric control system, and the safety evaluation result that complete machine is overall.
8. portal crane health monitoring according to claim 1 and forecast visualization system, is characterized in that, described central server structure MYSQL database cluster, redis data-base cluster and MongoDB data-base cluster; By described MYSQL database cluster, distributed storage original data and analysis result data; By described redis data-base cluster, distributed storage real time data; By described MongoDB data-base cluster, distributed storage document data.
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| CN113353802B (en) * | 2021-05-17 | 2022-09-16 | 唐山不锈钢有限责任公司 | Device and method for automatically judging degradation of crown block wheel and track |
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