CN111675106A - Intelligent grab bucket system based on Internet of things and monitoring method - Google Patents
Intelligent grab bucket system based on Internet of things and monitoring method Download PDFInfo
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- CN111675106A CN111675106A CN202010758128.XA CN202010758128A CN111675106A CN 111675106 A CN111675106 A CN 111675106A CN 202010758128 A CN202010758128 A CN 202010758128A CN 111675106 A CN111675106 A CN 111675106A
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- grab bucket
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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
- B66C13/18—Control systems or devices
- B66C13/22—Control systems or devices for electric drives
- B66C13/32—Control systems or devices for electric drives for operating grab bucket hoists by means of one or more electric motors used both for hosting and lowering the loads and for opening and closing the bucket jaws
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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
- B66C13/18—Control systems or devices
- B66C13/46—Position indicators for suspended loads or for crane elements
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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
- B66C3/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith and intended primarily for transmitting lifting forces to loose materials; Grabs
- B66C3/04—Tine grabs
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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
- B66C3/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith and intended primarily for transmitting lifting forces to loose materials; Grabs
- B66C3/12—Grabs actuated by two or more ropes
- B66C3/125—Devices for control
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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
- B66C3/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith and intended primarily for transmitting lifting forces to loose materials; Grabs
- B66C3/14—Grabs opened or closed by driving motors thereon
- B66C3/18—Grabs opened or closed by driving motors thereon by electric motors
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Automation & Control Theory (AREA)
- Control And Safety Of Cranes (AREA)
Abstract
The invention is suitable for the technical field of grab buckets, and provides an intelligent grab bucket system and a monitoring method based on the Internet of things; the method comprises the following steps: the system comprises a grab bucket, a grab bucket video image system, a grab bucket geophysical prospecting system, a grab bucket hoisting monitoring protection system and an Internet of things data acquisition control system; the grab video image system is used for remotely transmitting the field image to the control room in real time; the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object; the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, a grab bucket steel wire rope tension, grab bucket overload, steel wire rope fracture and a frequency converter; the data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, and can record and retrieve data, judge accident reasons and control the system. The invention realizes the remote intelligent monitoring function of the grab bucket, thereby comprehensively monitoring the grab bucket.
Description
Technical Field
The invention relates to the technical field of grab buckets, in particular to an intelligent grab bucket system based on the Internet of things and a monitoring method.
Background
Traditional jack-up grab bucket still is mostly semi-automatization's operation mode, lack the monitoring measure among the grab bucket operation process, whole operation of snatching is mastered by operating personnel entirely, mechanical life to the grab bucket does not evaluate, to the grab bucket motor, wire rope does not have the monitored data as the reference, often the accident is high, more can't accomplish centralized management, can not remote monitoring, even individual hardware equipment reaches life and still is moving in violation of rules and regulations, grab bucket control system poor stability, in abominable operational environment, often because of high temperature, high humidity, external factors such as high dust lead to the grab bucket trouble, shut down even, more probably cause economic loss or even casualties.
Disclosure of Invention
The invention aims to provide an intelligent grab bucket system based on the Internet of things and a monitoring method, so as to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme:
an wisdom grab system based on thing networking includes: the system comprises a grab bucket, a grab bucket video image system, a grab bucket geophysical prospecting system, a grab bucket hoisting monitoring protection system and an Internet of things data acquisition control system;
the grab bucket video image system is used for remotely transmitting the field image to the control room in real time;
the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object;
the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, grab bucket steel wire rope tension, grab bucket overload, steel wire rope breakage and a frequency converter.
The data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, can record and retrieve data, judges accident reasons and controls the system.
As a further scheme of the invention: the grab bucket geophysical prospecting system comprises a material sensor module, two ultrasonic transducers, a main control board C and a limiting module.
As a still further scheme of the invention: the grab bucket hoisting monitoring and protecting system comprises a lifting limit module, a main control board A, a hoisting motor power supply monitoring device, a bucket opening and closing motor power supply monitoring device, a frequency converter monitoring device, a grab bucket overload protection device, a grab bucket suction relay auxiliary device, a grab bucket steel wire rope tension monitoring device, a steel wire rope fracture monitoring device and grab bucket opening and closing monitoring, and edge monitoring and protecting functions are realized.
As a still further scheme of the invention: the grab bucket video image system comprises an image acquisition module, a main control board B, a video and audio transmission DTU remote transmission module and a terminal image analysis and display device.
As a still further scheme of the invention: the data acquisition control system of the Internet of things comprises a system data server, a remote control terminal and a terminal data receiving and processing module.
As a still further scheme of the invention: the two ultrasonic transducers form an ultrasonic transducer array.
As a still further scheme of the invention: still include the audio-visual system of grab bucket, the audio-visual system of grab bucket is independent of control system.
The invention provides another technical scheme as follows:
a monitoring method of an intelligent grab bucket based on the Internet of things is characterized by comprising the following steps:
the grab video image system remotely transmits the field image to the control room in real time by the grab;
the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object;
the grab bucket object detection system adopts a transducer array to carry out distance detection on a grabbed object;
the grab bucket geophysical prospecting system adopts a crosstalk inhibition method based on pseudo-random codes to carry out anti-interference acquisition on echo waves;
the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, a grab bucket steel wire rope tension, grab bucket overload, steel wire rope fracture and a frequency converter;
the data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, and can record and retrieve data, judge accident reasons and control the system.
As a further scheme of the invention: the method comprises the following steps of (1) adopting a transducer array to carry out distance detection on a grabbed object, wherein the measuring steps are as follows: the grab bucket is started, the first steel wire rope descends, and meanwhile, the grab bucket is opened;
when the grab bucket is close to a grabbed object, a transducer array formed by two ultrasonic transducers receives returned ultrasonic sound waves in real time, a control panel C of the geophysical prospecting subsystem analyzes and processes an echo angle and echo duration, and echo attributes are distinguished in a pseudo-random code crosstalk inhibition mode; the control panel C calculates the echo distance through a transit time method, judges the surface shape of the grabbed object by means of the echo angle, and when the reflected echo can be received, the grabbed object on the surface has no large inclination angle and no section, and when the transducer cannot receive the echo due to the overlarge echo reflection angle, the grabbed object has a large inclined plane;
critical points of the grabbed objects and the storage space are analyzed and judged, and hard collision between the grab bucket and a cabin or a wall and the like is avoided;
according to the echo angle, the echo transmission distance and the storage critical point, the appearance shape of the grabbed object is modeled, and when the grab bucket automatically grabs, the model is built for the grabbed object, the high point of the object is preferentially grabbed, the hard collision with the grabbed object is reliably avoided, and the intelligent grabbing is realized.
As a still further scheme of the invention: the ultrasonic transducer array calculates the transmission distance of sound waves by adopting a transit time method.
Compared with the prior art, the invention has the beneficial effects that: the video image system of the grab bucket can acquire the real-time situation of the grab bucket operation site through the video acquisition module and the audio acquisition module and transmit the situation to the data acquisition control system of the Internet of things; the grab bucket geophysical prospecting system judges the high points and the depression of the material, models and judges the shape and the distance of the grabbed object; the grab bucket hoisting monitoring protection system carries out real-time parameter measurement on an alternating current three-phase power supply, an alternating current lifting and switching motor, four groups of steel wire ropes, upper and lower limit positions and the like of the grab bucket, all signals are directly input into corresponding ports of a hoisting monitoring control board A, and finally all monitoring signals are remotely transmitted to an Internet of things data acquisition control system; thing networking data acquisition control system receives all data that come from grab bucket video image system, grab bucket geophysical prospecting system and grab bucket jack-up control protection system, accomplish to data and pass through and receive and correspond the server address storage, managers and user can visit thing networking data acquisition control system's server through remote control terminal, realize the long-range wisdom monitoring function to the grab bucket, and then monitor the grab bucket comprehensively, effectively reduce the equipment impact, improve the security and the reliability in the aspect of grab bucket machinery and electricity, reduce operation driver fatigue degree, improve the degree of automation that the grab bucket got the material.
Drawings
Fig. 1 is a control structure schematic diagram of an intelligent grab bucket system based on the internet of things.
Fig. 2 is a schematic structural diagram of a grab bucket in an intelligent grab bucket system based on the internet of things.
Fig. 3 is a data transmission schematic diagram of an intelligent grab bucket system based on the internet of things.
Fig. 4 is a schematic diagram of the operation of an ultrasonic transducer array in an intelligent grab bucket system based on the internet of things.
Fig. 5 is a schematic diagram of calculating a sound wave transmission distance by a transit time method in an intelligent grab system based on the internet of things.
Fig. 6 is a schematic diagram of a pseudo-random sequence autocorrelation function in an intelligent grab bucket system based on the internet of things.
In the figure: the system comprises a first steel wire rope 1, a lateral pressure type sensor 2, a second steel wire rope 3, a tearing sensor 4, a grab bucket central control box 5, a grab bucket opening and closing mechanism 6, an image acquisition module 7, a material sensor 8, an ultrasonic transducer 9, a grab bucket 10, a grab bucket supporting arm 11 and a guide wheel group 12.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, a structure diagram of an intelligent grab system based on the internet of things provided in an embodiment of the present invention includes: the system comprises a grab bucket, a grab bucket video image system, a grab bucket geophysical prospecting system, a grab bucket hoisting monitoring protection system and an Internet of things data acquisition control system;
the grab bucket video image system is used for remotely transmitting the field image to the control room in real time;
the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object;
the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, grab bucket steel wire rope tension, grab bucket overload, steel wire rope breakage and a frequency converter.
The data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, can record and retrieve data, judges accident reasons and controls the system.
The grab bucket geophysical prospecting system comprises a material sensor module, two ultrasonic transducers 9, a main control board C and a limiting module.
The material quality sensor module adopts the prior art, and specifically can select Shanghai Jia Tang JT-L2 type equipment.
The grab bucket hoisting monitoring and protecting system comprises a lifting limit module, a main control board A, a hoisting motor power supply monitoring device, a bucket opening and closing motor power supply monitoring device, a frequency converter monitoring device, a grab bucket overload protection device, a grab bucket suction relay auxiliary device, a grab bucket steel wire rope tension monitoring device, a steel wire rope fracture monitoring device and grab bucket opening and closing monitoring, and edge monitoring and protecting functions are realized.
The power supply monitoring device of the hoisting motor is used for monitoring instantaneous current, voltage and phase sequence of the power supply.
The power supply monitoring device of the open-close bucket motor is used for monitoring instantaneous current, voltage and phase sequence of a power supply.
The grab bucket video image system comprises an image acquisition module 7, a main control board B, a video and audio transmission DTU remote transmission module and a terminal image analysis and display device.
The data acquisition control system of the Internet of things comprises a system data server, remote control terminal software (a mobile app end and a PC end) and a terminal data receiving and processing module.
The control panel A, B, C adopts STM32 series MCU as core control unit; on one hand, the chip is the most popular chip at present, the performance is reliable and stable, on the other hand, the communication between chips of the same type is easier to write and debug, debugging programs and application software are simplified, and the system stability is improved.
Firstly, a control panel B and an independent DTU transparent transmission module in a video image system form a data processing and transmission channel, and the subsystem transmits data to a physical network data acquisition control subsystem through the independent DTU module after acquiring grab bucket field data through the image module; secondly, the geophysical prospecting system is provided with a control panel C, and the control panel C transmits geophysical prospecting data to the hoisting monitoring subsystem through an onboard serial data interface; thirdly, the hoisting monitoring subsystem is provided with a control panel A, on one hand, the control panel A receives geophysical prospecting data of the control panel C through a serial port, on the other hand, a panel A collects parameter data of all monitoring points of the system, and then all data of the geophysical prospecting and hoisting monitoring subsystems are transmitted to the Internet of things data acquisition control subsystem through a DTU module which is designed and carried by the control panel A; and finally, the Internet of things data acquisition control subsystem receives, analyzes and processes the acquired data of the other 3 subsystems in an Internet of things wireless transmission mode, stores monitoring parameters of all points, and provides a control input port and display data for a manager.
As shown in fig. 2, the grab bucket comprises at least two first steel wire ropes 1, at least two second steel wire ropes 3, a grab bucket opening and closing mechanism 6, a grab bucket 10 and a grab bucket supporting arm 11, wherein the first steel wire ropes 1 are supporting steel wire ropes of the grab bucket and are responsible for lifting and descending of the whole grab bucket, and the lifting and descending of the steel wire ropes are determined by positive rotation and negative rotation of a lifting motor; the second steel wire rope 3 is a bucket opening and closing steel wire rope of the grab bucket, when the two steel wire ropes are lifted, the grab bucket is closed, and when the two steel wire ropes are reversed, the bucket is released by the self weight of the grab bucket mechanism;
the first steel wire rope 1 and the second steel wire rope 3 respectively penetrate through stress pressure variable sheets on the side pressure type sensor 2, when the side pressure type sensor 2 is stressed, the side pressure type sensor 2 outputs pressure signals of 4-20 ma, the pressure signals are transmitted to the grab bucket control box 5, and the signals are subjected to tangential value calculation of a vertical angle, namely, vertical tension values borne by the first steel wire rope 1 and the second steel wire rope 3;
all be provided with tear sensor 4 on first wire rope 1 and the second wire rope 3, tear sensor 4 can realize passing wire rope cross-section real-time supervision wherein, when 1 and second wire rope 3's sectional area appears changing (can only reduce usually), then send rupture signal to the control panel A in the wisdom grab control box 5 immediately, judge whether for wire rope breaks, control panel A random send order cuts off each motor power, stops the grab operation and reports to the police.
The intelligent grab control box 5 integrates a control panel A, B, C and a corresponding DTU module thereof, receives all monitoring parameters of the field grab and an emergency treatment output terminal, the control panels A, C are connected by serial ports, and are provided with wireless remote transmission 4G antennas, so that data interconnection with a remote Internet of things database is realized (see the attached figure 3 in detail).
The grab bucket opening and closing mechanism 6 is connected with the second steel wire rope 3 and is a movable pulley mechanism, and the grab bucket opening and closing motor rotates in the positive direction to drive the second steel wire rope 3 to tighten and wind the roller or send and release the steel wire rope, so that the functions of opening and closing the grab bucket of the grab bucket mechanism shovel 10 are finally realized.
The image acquisition module 7 is fixedly arranged on the grab bucket opening and closing mechanism 6 and is responsible for acquiring sound and image data of a grab bucket site and providing the most intuitive video evidence data for a manager of the remote control terminal;
the material sensor 8 is fixedly arranged on the grab bucket 10 and used for detecting whether materials or steel plates or other structural objects are in front of the grab bucket, so that accidents caused by mistaken touch of the grab bucket are prevented;
the ultrasonic transducers 9 are fixedly arranged on the grab bucket 10, and the two ultrasonic transducers 9 form an ultrasonic transducer array which is a core sensor component of the grab geophysical prospecting subsystem;
the grab bucket supporting arm 11 bears the net weight of the grab bucket and the weight of a grabbed object allowed by the bucket capacity, and the two ends of the grab bucket supporting arm are hinged to realize rotation at a certain angle;
one end of the guide wheel group 12 is connected with a steel wire rope winding drum of the opening and closing bucket motor, the other end of the guide wheel group is connected with the opening and closing bucket mechanism 6, the working position of the steel wire rope can be fixed through the guide wheel group, the steel wire rope is prevented from falling off, hard friction between the steel wire rope and other mechanical structures is avoided, and the service life of the steel wire rope is prolonged.
The grab bucket is four-rope opening and closing bucket type grab bucket, the total number of the four steel wire ropes is four, and the first steel wire rope 1 and the second steel wire rope 3 are two.
The material sensor can distinguish that the material of the grabbed object is different from that of the storage space, and judge the edge of the grabbed object; the said 9 is array structure, adopt and receive, send the transducer group that the transducer makes up, the ultrasonic wave that A transducer sends can be received by A, B two transducers; the S control panel C is a central control panel of the system, identifies and processes material sensor data, extracts and analyzes sound waves of the transducer group, protects the grab bucket from hard collision with materials by means of the limiting module, and simultaneously, the control panel C designs a serial port communication circuit and can transmit all data of the system to a main control panel A of the grab bucket lifting monitoring and protecting system.
The lifting limiting module limits the highest position and the lowest position of the grab bucket, the high limit can prevent the grab bucket from physically and hard colliding with a large machine arm, and the low limit can prevent the first steel wire rope 1 of the grab bucket from being released beyond the actual length to cause the first steel wire rope 1 to be loosened or wound. The main control board A (STM32 series MCU) also adopts STM32 series MCU as a core control unit, is responsible for acquiring all monitoring signals under the system, simultaneously receives and processes geophysical prospecting data transmitted by the geophysical prospecting system control board C, comprehensively judges the working condition of the operation grab bucket, realizes real-time edge control of the grab bucket, and simultaneously merges and uploads the data of the two systems to the remote data acquisition system of the Internet of things; the power supply of the lifting bucket motor and the bucket motor can be monitored, and the current, the voltage and the phase sequence of an alternating current three-phase power supply can be monitored in real time; the frequency converter is used for monitoring, and parameters of the motor starting frequency converter can be monitored; the grab bucket overload protection device is used for cutting off a power supply of the grab bucket in real time and unloading the grab bucket when the grab bucket is detected to be overloaded because the grabbed objects exceed the maximum weight which can be actually borne by the grab bucket; the grab bucket suction times are signal acquisition and accumulation of contacts of the motor start-stop auxiliary relay, and when the suction times of a start-stop motor and an on-off motor of the grab bucket reach a set upper limit, an alarm is given to prompt the replacement of new equipment; grab bucket wire rope pulling force monitoring devices, wire rope fracture monitoring devices, every first wire rope 1 and every second wire rope 3 of grab bucket are equipped with side pressure formula sensor 2 and prevent fracture sensor 4, the pulling force value that this wire rope bore of real-time measurement can be measured to side pressure formula sensor 2, tear sensor 4 can real-time supervision steel cable cross-section and whether have the rope silk condition of rupture, the signal value real-time transfer of two sensors gives grab bucket jack-up monitoring protection system control panel A, the control panel makes the judgement to wire rope's pulling force value and rope cross-section condition of rupture, pass through thing networking teletransmission with digital signal's form simultaneously and give thing networking data acquisition control system.
If data abnormality occurs in the grab bucket site, for example, the tensile value of the steel wire rope exceeds a threshold value or the rope section becomes small, the grab bucket hoisting monitoring and protecting system automatically cuts off the power supply of the steel wire rope motor, stops the grab bucket operation and sends out warning information at the same time.
Grab bucket jack-up control protection system has the function of all-round, digital control and uses the grab bucket as the electric, mechanical equipment of core, the grab bucket is typical four-rope grab bucket control system, and all on-the-spot monitoring signal pass through the bus and transmit for main control board A, and the 4G module of thing networking grab bucket main control board can give data acquisition control system with the wireless teletransmission of collection processing result, and the control point of this main control board is as follows:
monitoring point a: wherein two first wire rope 1 are the stay cord, the effect is for promoting or descending whole grab bucket mechanism, every first wire rope 1 is equipped with side pressure formula sensor 2 and prevents sensor 4 that splits, side pressure formula sensor 2 can measure the pulling force value that this wire rope bore in real time, prevent that sensor 4 that splits can real-time supervision steel cable cross-section whether has the rope silk fracture condition, the signal value real-time transfer of two sensors gives grab bucket jack-up monitoring protection system central control panel, control panel A makes the judgement to the pulling force value of wire rope and the rope cross-section fracture condition, pass through thing networking teletransmission for thing networking data acquisition control system with digital signal's form simultaneously. If data abnormality occurs in the grab bucket site, for example, the tensile value of the steel wire rope exceeds a threshold value or the rope section becomes small, the grab bucket hoisting monitoring and protecting system automatically cuts off the power supply of the steel wire rope motor, stops the grab bucket operation and sends out warning information at the same time.
Monitoring point b: the second steel wire rope 3 is used for opening or closing the grab bucket to realize the grabbing function of materials, and the side pressure tension sensor 2 and the rope breakage-preventing sensor 4 are also arranged on the rope and have the same function as the monitoring point a.
And c, monitoring point c: the grab bucket limiting module is used for limiting the lifting height and the descending height of the grab bucket, the actual lifting height and the descending height of the grab bucket are related to the winding length of the steel wire rope, and if the lifting height exceeds the highest limiting module, the grab bucket and the steel wire rope winding drum collide, so that mechanical accidents are caused; if the descending height is lower than the lowest limit module, the steel wire rope can be unhooked, or the grab bucket is stopped but the steel wire rope winding drum continues to rotate, so that the winding drum motor burns out.
Monitoring point d: the power supply monitoring device for the lifting motor monitors the voltage, the current and the phase sequence of three-phase power of a power supply A, B, C of the lifting motor in real time, and can immediately give an alarm if faults such as overvoltage, undervoltage, overcurrent and phase error occur, and simultaneously cut off the power supply of the motor.
Monitoring point e: and the power supply monitoring device of the opening and closing bucket motor is the same as the monitoring point d.
Monitoring point f: the frequency converter monitoring device protects the running parameters of the motor in real time, monitors the impact degree of the motor on the main power grid after the motor is started and stopped after softening, and plays a certain role in protecting the upper-level main power grid of the power supply while monitoring and protecting the grab bucket motor.
Monitoring point g: the grab bucket overload protection device is characterized in that the grab buckets are provided with rated grabbing amount threshold values, when the system monitors that the tension of the steel wire rope and the current of the power supply reach or exceed the set threshold values, the system automatically alarms, the power supply of the motor is cut off, and meanwhile, the overload warning information of the grab buckets is sent out.
Monitoring point h: the grab bucket actuation times are used for collecting signals of the motor start-stop auxiliary relay contacts and accumulating the signals, when the actuation times of the grab bucket lift motor and the motor start-stop motor reach set upper limits, the service life of the motor is close to the accident high-rise period, and warning information is sent to give out a new motor, so that the effect of protecting grab bucket complete equipment is achieved, and the serious consequences caused by over-fatigue use is avoided.
Monitoring point i: the grab bucket steel wire rope tension monitoring device and the steel wire rope fracture monitoring device are shown in detail in monitoring points a and b.
Monitoring point j: the grab bucket is opened and closed for limiting, the grab bucket opening and closing bucket steel wire rope is provided with an opening bucket and a closing bucket for limiting, when the empty grab bucket descends, the grab bucket is opened, the grab bucket closing bucket steel wire rope descends, the bucket part is opened by the self weight of the grab bucket, the continuous bucket opening is stopped when the bucket opening limit is reached, otherwise, the steel wire rope is easy to loosen, and the grab bucket is out of control; when the grab bucket grabs materials and rises, the steel wire rope rises, the grab bucket is closed, the grab bucket stops closing the grab bucket when the grab bucket reaches the position limiting of closing the grab bucket, otherwise, the tensile force of the steel wire rope of the opening and closing bucket can rise sharply (the grab bucket part is closed), and the steel wire rope can be broken when the grab bucket is serious.
The terminal data receiving and processing module is a module for carrying out protocol analysis, address allocation and server register butt joint on data which is remotely transmitted by each field system through a DTU (data transfer unit), so that accurate storage of the data in a remote data server is realized; the remote data server can select a network or a local server, and can be used for developing the server and building a software system to connect various data transmitted from a field, so that the remote data server can be used for data access application of a terminal user on one hand, and can store remote data in real time on the other hand, thereby providing technical support for data query; the remote control terminal (mobile app and pc end) is an application interface opened for users, managers or users can monitor the operation grab bucket in real time through app or pc application programs, data display is visual, parameters of the grab bucket can be set in real time through the terminal, and the trouble of local field modification is avoided.
The invention also comprises a grab bucket audio-video system which is independent of the control system, thus reducing the complexity of system processing, improving the system operation efficiency and realizing the access and storage functions of the remote server.
The invention integrates multiple key technologies such as mechanical and motor technologies, sensing and communication networks and the like, and adopts a plurality of microprocessing units to coordinate and distribute the sensing detection units and the information processing, driving and control execution units at multiple points in a large system to cooperatively work in order, thereby improving the intelligent degree and the working efficiency of the grab bucket.
As shown in fig. 3, a data transmission diagram of an intelligent grab bucket of the internet of things is shown, and the intelligent grab bucket system of the invention is divided into a field operation part, a database server part and a terminal data processing part. When data are transmitted forwards, a grab bucket of a field operation part acquires field sensor parameters by means of an autonomously developed control panel, and transmits the data to a remote database server in a wireless Internet of things mode through a DTU (data transfer unit) module or a module and by means of a mobile signal base station; the database server is responsible for classifying and storing data transmitted from a field, and opens ports for mobile phones, PCs and large screen ends of the terminals to apply through internet protocols; when data is transmitted reversely, a manager of the terminal can also reversely modify the setting parameters of the application program through input equipment such as a mobile phone, a PC and the like, the newly modified parameters are transmitted to a remote server through the Internet and modify a server register, the register immediately issues an instruction, and the grab bucket for field operation is controlled through the Internet and a mobile base station.
As shown in fig. 4, the ultrasonic transducer 9 array is used for acoustic ranging of the grabbed objects. The grab bucket adopts the ultrasonic ranging method to measure the distance and the shape of the grabbed object, the ultrasonic collecting and transmitting integrated device is the ultrasonic transducer 9, and the single transducer has a limited measuring range and can not easily receive feedback sound waves; if the transducer fails to receive the echo, it indicates a large dip, i.e., a puddle, in the area being probed. When the material is grabbed by the grab bucket, the materials with echo signals can be grabbed mainly, and the materials with shorter detection distance can be grabbed automatically from top to bottom.
When the grab bucket automatically grabs, the analog input port of the control panel C receives and processes the ultrasonic signal transmitted by the transducer, the signal is a 4-20 ma analog signal, the signal is subjected to analog-to-digital conversion processing on the control panel C, the distance between the material and the grab bucket is judged, and the shape of the material is judged through the feedback angle of sound waves. And no signal feedback condition occurs in the moving process of the grab bucket, which indicates that the reflected wave cannot be received by the transducer due to overlarge inclination angle, and the grab bucket automatically translates to search for a material point which is closer to the grab bucket and can acquire signals. In the process, the ultrasonic transducer 9 arrays can transmit and receive each other, and an anti-interference mechanism is added, so that the accuracy of detecting the grabbed objects is ensured.
The embodiment of the invention also provides a monitoring method of the intelligent grab bucket based on the Internet of things, which comprises the following steps:
the grab video image system remotely transmits the field image to the control room in real time by the grab;
the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object;
the grab bucket object detection system adopts a transducer array to carry out distance detection on a grabbed object;
the grab bucket geophysical prospecting system adopts a crosstalk inhibition method based on pseudo-random codes to carry out anti-interference acquisition on echo waves;
the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, a grab bucket steel wire rope tension, grab bucket overload, steel wire rope fracture and a frequency converter;
the data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, can record and retrieve data, judges accident reasons and controls the system.
As shown in fig. 4, an embodiment of the present invention further provides a method for measuring distance of an intelligent grab bucket based on the internet of things, where a transducer array is used to perform distance detection on a grabbed object, and the measuring steps are as follows:
step 1: the grab is started, the first steel wire rope 1 descends, and meanwhile, the grab bucket 10 is opened;
specifically, the intelligent grab bucket is started, the motor is supported to rotate forwards, the steel wire rope is supported to descend, the bucket opening motor rotates forwards, the bucket shovel is opened when the grab bucket descends, and the working efficiency is improved;
step 2: when the grab bucket is close to a grabbed object, a transducer array formed by two ultrasonic transducers 9 receives returned ultrasonic sound waves in real time, a control panel C of the geophysical prospecting subsystem analyzes and processes an echo angle and echo duration, and echo attributes are distinguished in a pseudo-random code crosstalk inhibition mode;
and step 3: the control panel C calculates the echo distance through a transit time method, judges the surface shape of the grabbed object by means of the echo angle, and when the reflected echo can be received, the grabbed object on the surface has no large inclination angle and no section, and when the transducer cannot receive the echo due to the overlarge echo reflection angle, the grabbed object has a large inclined plane;
and 4, step 4: by means of the material sensor module, critical points of the grabbed objects and the storage space are analyzed and judged, and hard collision between the grab bucket and a cabin or a wall and the like is avoided;
and 5: according to the echo angle, the echo transmission distance and the storage critical point, the appearance shape of the grabbed object is modeled, and when the grab bucket automatically grabs, the model is built for the grabbed object, the high point of the object is preferentially grabbed, the hard collision with the grabbed object is reliably avoided, and the intelligent grabbing is realized.
As shown in fig. 5, the ultrasonic transducer 9 array calculates the acoustic transmission distance by using a transit time method. The transit time method is easier to realize in software design and hardware design compared with other methods, and works stably, and the basic principle is that the propagation distance is obtained by multiplying the speed of a ship with a measured object in a medium by time. The invention applies the transit time method to ultrasonic ranging as a method for calculating the distance between the grab bucket and the grabbed object, and the total path from the self-emission to the receiving of the ultrasonic is twice of the distance between the grab bucket and the grabbed object.
The propagation velocity of the ultrasonic wave in air can be expressed as:
wherein gamma is the ratio of the specific heat capacity at constant pressure of the gas to the specific heat capacity at constant volume, and is 1.40 under the standard condition; q is a gas universal constant, and the value under the standard state is 8.314 J.mol < -1 >. k < -1 >; r is gas molecular weight, and the standard value is 28.8 multiplied by 10 < -3 > kg.mol < -1 >; t denotes the thermodynamic absolute temperature.
Under the standard condition, Q is constant, and the gamma and R, T change slightly, so that the influence on the ultrasonic sound velocity is small and can be ignored. The relationship of the speed of sound v to the ambient temperature T can therefore be expressed in simplified form as:
the detection distance s is then:
wherein the sound wave velocity v0 of zero degree centigrade is 331.5m/s, and the sound wave velocity of 30 degree centigrade is 350 m/s; t0 denotes the absolute temperature T0 ═ 273.15K at zero degrees celsius; the value T of the thermodynamic temperature T is T0+ X is 273.15K + X, and X refers to the actual temperature in centigrade; t refers to the transit time; l refers to the total path taken by the sound wave from emission to return.
The invention adopts a crosstalk suppression method based on pseudo-random codes to carry out anti-interference acquisition on the echo waves. The ultrasonic transducer 9 array echo acquisition adopts a crosstalk inhibition method, which means that a pseudo-random sequence has the characteristics of sharp self-correlation and flat cross-correlation, and an excitation sequence is constructed by combining the modulation idea so as to inhibit the internal crosstalk of the echo, realize the simultaneous receiving and transmitting of multiple transducers in a transducer array, reduce the time of distance measurement and improve the real-time property of data.
As shown in fig. 6, the Pseudo Random Code (PN Code, Pseudo Noise Code) is a Code having a white Noise-like property, and is also called a Pseudo Random (Pseudo Noise) sequence. White noise is a random process, instantaneous values follow a normal distribution, a power spectrum is uniform in a wide frequency band and has excellent correlation characteristics, an autocorrelation function of the white noise is similar to a function, most pseudo random codes are periodic codes and can be artificially generated and copied and are usually generated by a binary shift register. The pseudo-random code has the property of white noise, the correlation function has the sharp characteristic, the power spectrum occupies a wide frequency band, and therefore, the pseudo-random code is easy to separate from other signals or interference and has excellent anti-interference characteristic.
Applying the pseudo-random sequence coding modulation to the ultrasonic ranging system is equivalent to endowing each path of ultrasonic transducer with a single mark, so that the ultrasonic transducers in different paths in the ranging system can make a correct judgment on whether the echo is a reflection echo of an ultrasonic signal sent by the ultrasonic transducers. In order to avoid interference between two paths of different reflected echoes, the difference between different code modulation excitation sequences is increased. And evaluating the difference or similarity between the respective excitation sequences of the two ultrasonic transducers, and introducing a correlation function.
Autocorrelation function for coding excitation sequence
Cross correlation function of coded excitation sequences
Wherein XT refers to the number of excitation sequences and refers to the ith value of the jth return wave sample; refers to the i + x value of the jth return sample; the ith value of the g-th return wave sample is indicated, the total number of sampling points of the x pointer to the return wave is indicated, and x indicates the number of shifting bits.
The correlation function represents the similarity degree of two time domain signals, and in the ultrasonic ranging process, the smaller the similarity of excitation sequences generated by combining the same type of coding modulation modes is, the easier the ultrasonic transducer can identify ultrasonic echo signals emitted by the ultrasonic transducer, and the stronger the ultrasonic crosstalk elimination capability is.
The similarity of sound wave echoes emitted by the transducers represented by the cross-correlation function is characterized in that sound wave signals of the same transducer have fixed frequency, the ultrasonic amplitude value can change along with the change of distance when the sound wave signals are transmitted in the air, the frequency can be kept basically unchanged, periodic signals are only related to periodic signals with the same frequency according to the characteristics of a related algorithm, the time difference of the two periodic signals with the same frequency and the peak value of the signals are at the same moment, and non-periodic signals or other periodic excitation sequence signals can be successfully identified and eliminated.
The autocorrelation function represents the similarity of the same time domain signal at two different time points, the smaller the side lobe value of the echo autocorrelation function generated by the excitation sequence generated by combining the same type of coding modulation modes is, the easier the echo sequence matched with the autocorrelation function can be identified by the correlation rule, and the more the transition time point corresponding to the peak value of the main function can be accurately captured, thereby effectively preventing signal crosstalk and wrong ranging values.
The excitation sequence is constructed by adopting a pseudo-random code modulation method, so that the internal crosstalk of the echo can be inhibited, more accurate transition time can be obtained by adopting correlation operation at a receiving end, and the ultrasonic transducer can transmit a long sequence: because the autocorrelation is sharp, the timing end point can be replaced by the moment when the autocorrelation value exceeds the threshold value and is the maximum value in a period of time, and the anti-interference capability of the ranging system is improved; the emission long sequence represents the increase of emission energy, so that the effective ranging range is greatly increased, and related operations are adopted at a receiving end for pulse compression, so that the advantages of improving ranging precision, stabilizing ranging resolution, increasing effective measuring distance and the like are achieved, and the shape of the measured object is favorably identified.
The grab bucket video image system can acquire real-time conditions of a grab bucket operation site through the video acquisition module and the audio acquisition module, acquired signals are remotely transmitted to the Internet of things data acquisition control system through the DTU wireless transparent transmission module, a transmission channel and data are isolated from other 3 subsystems, and independent protective transmission is adopted, so that the stability and the transmission rate of the channel are increased; the grab bucket geophysical prospecting system comprises an energy converter array formed by ultrasonic energy converters, when the grab bucket works, a control panel C receives ultrasonic echo signals reflected by a grabbed object, a program introduces a crosstalk suppression algorithm to automatically analyze signal data, a transit time method is utilized to calculate the distance from the grab bucket to the grabbed object, the high point and the depression of the object are judged according to the collected echo reflection angle, and the shape and the distance of the grabbed object are judged through modeling; the grab bucket hoisting monitoring protection system carries out real-time parameter measurement on an alternating current three-phase power supply, an alternating current lifting and switching motor, four groups of steel wire ropes, upper and lower limit positions and the like of the grab bucket, all signals are directly input into corresponding ports of a hoisting monitoring control board A, and finally all monitoring signals are remotely transmitted to an Internet of things data acquisition control system through a DTU module; the internet of things data acquisition control system receives all data from the grab bucket video image system control panel B and the hoisting monitoring control panel A, data are transmitted and received and stored in corresponding server addresses, meanwhile, mobile phone end app and PC end smart grab bucket application programs are developed, managers and users can access the server of the internet of things data acquisition control system through the app and the PC ends, and the remote smart monitoring function of the grab bucket is achieved.
All subsystem control boards A, B, C of the invention adopt STM32 series MCU as core control units, on one hand, the chip is the most popular chip at present, the performance is reliable and stable, on the other hand, the communication between chips of the same type is easier to compile and debug, the debugging program and the application software are simplified, and the system stability is improved.
The video image subsystem of the invention transmits data independently, improves the speed and stability of data transmission, and reduces the problem of blocking caused by centralized transmission of the system.
All field data are transmitted remotely through the Internet of things system, and wireless, remote and real-time operation can be realized.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (10)
1. The utility model provides an wisdom grab bucket system based on thing networking which characterized in that includes: the system comprises a grab bucket, a grab bucket video image system, a grab bucket geophysical prospecting system, a grab bucket hoisting monitoring protection system and an Internet of things data acquisition control system;
the grab bucket video image system is used for remotely transmitting the field image to the control room in real time;
the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object;
the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, a grab bucket steel wire rope tension, grab bucket overload, steel wire rope fracture and a frequency converter;
the data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, can record and retrieve data, judges accident reasons and controls the system.
2. The intelligent Internet of things-based grab bucket system of claim 1, wherein the grab bucket geophysical prospecting system comprises a material sensor module, two ultrasonic transducers, a main control board C and a limiting module.
3. The intelligent grab bucket system based on the internet of things as claimed in claim 1, wherein the grab bucket lifting monitoring and protecting system comprises a lifting limit module, a main control panel A, a lifting motor power supply monitoring device, an opening and closing bucket motor power supply monitoring device, a frequency converter monitoring device, a grab bucket overload protection device, a grab bucket suction relay auxiliary device, a grab bucket steel wire rope tension monitoring device, a steel wire rope fracture monitoring device and grab bucket opening and closing monitoring, and edge monitoring and protecting functions are realized.
4. The intelligent Internet of things-based grab bucket system of claim 1, wherein the grab bucket video image system comprises an image acquisition module, a main control board B, a video and audio transmission DTU (digital television Unit) remote transmission module and a terminal image analysis and display device.
5. The intelligent grab bucket system based on the internet of things as claimed in claim 1, wherein the internet of things data acquisition control system comprises a system data server, a remote control terminal and a terminal data receiving and processing module.
6. The internet of things-based smart grapple system of claim 2, wherein the two ultrasonic transducers comprise an ultrasonic transducer array.
7. The intelligent Internet of things-based grab system of claim 1, further comprising a grab audio and video system, wherein the grab audio and video system is independent of the control system.
8. The monitoring method of the intelligent grab bucket based on the internet of things as claimed in any one of claims 1-7, characterized by comprising the following steps:
the grab video image system remotely transmits the field image to the control room in real time by the grab;
the grab bucket geophysical prospecting system is used for processing and analyzing the appearance and the texture of a grab bucket grabbed and automatically judging the distance and the shape of the grabbed object;
the grab bucket object detection system adopts a transducer array to carry out distance detection on a grabbed object;
the grab bucket geophysical prospecting system adopts a crosstalk inhibition method based on pseudo-random codes to carry out anti-interference acquisition on echo waves;
the grab bucket lifting monitoring and protecting system is used for monitoring a grab bucket lifting motor power supply, a switch bucket motor power supply, a grab bucket steel wire rope tension, grab bucket overload, steel wire rope fracture and a frequency converter;
the data acquisition control system of the Internet of things is used for remote data acquisition, supervision and control, and can record and retrieve data, judge accident reasons and control the system.
9. The monitoring method of the intelligent grab bucket based on the internet of things as claimed in claim 8, wherein the transducer array is used for detecting the distance of the grabbed object, and the measuring steps are as follows:
the grab bucket is started, the first steel wire rope descends, and meanwhile, the grab bucket is opened;
when the grab bucket is close to a grabbed object, a transducer array formed by two ultrasonic transducers receives returned ultrasonic sound waves in real time, a control panel C of the geophysical prospecting subsystem analyzes and processes an echo angle and echo duration, and echo attributes are distinguished in a pseudo-random code crosstalk inhibition mode;
the control panel C calculates the echo distance through a transit time method, judges the surface shape of the grabbed object by means of the echo angle, and when the reflected echo can be received, the grabbed object on the surface has no large inclination angle and no section, and when the transducer cannot receive the echo due to the overlarge echo reflection angle, the grabbed object has a large inclined plane;
critical points of the grabbed objects and the storage space are analyzed and judged, and hard collision between the grab bucket and a cabin or a wall and the like is avoided;
according to the echo angle, the echo transmission distance and the storage critical point, the appearance shape of the grabbed object is modeled, and when the grab bucket automatically grabs, the model is built for the grabbed object, the high point of the object is preferentially grabbed, the hard collision with the grabbed object is reliably avoided, and the intelligent grabbing is realized.
10. The monitoring method for the intelligent grab bucket based on the internet of things as claimed in claim 8, wherein the ultrasonic transducer array calculates the sound wave transmission distance by adopting a transit time method.
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| CN113233331A (en) * | 2021-05-19 | 2021-08-10 | 海鼎自动化科技(靖江)有限公司 | Metering device mounted on portal crane |
| CN113493166A (en) * | 2021-07-28 | 2021-10-12 | 北京环境特性研究所 | Hoisting device |
| CN114057107A (en) * | 2021-11-25 | 2022-02-18 | 大连华锐重工集团股份有限公司 | Rope breakage detection system and method for lifting opening and closing mechanism of grab ship unloader |
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