CN115615487A - Online monitoring method for rotary trash remover and system for realizing method - Google Patents
Online monitoring method for rotary trash remover and system for realizing method Download PDFInfo
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Abstract
The invention belongs to the technical field of metal structure monitoring of hydroelectric engineering, and provides an online monitoring method of a rotary trash remover and a system for realizing the method; wherein, the method comprises the following steps: (1) Acquiring relevant data of the rotary trash remover in an operating state through a sensor; (2) processing the data collected by the sensor; and (3) generating a statistical curve and an operation report of online monitoring. The invention analyzes the operation of the rotary trash remover, and acquires the operation related data of the rotary trash remover by setting sensors and corresponding arrangement points thereof: the strain data, the sinusoidal vibration data, the random vibration data, the ultrasonic data, the pressure data, the vibration data and the torque data realize the real-time online monitoring of the running state and the like of the rotary trash remover, replace the regular manual inspection and the conventional inspection instrument adopted in the prior art, and provide new guarantee for the safe running of the rotary trash remover equipment.
Description
Technical Field
The invention belongs to the technical field of metal structure monitoring of hydropower and hydraulic engineering, and particularly relates to an online monitoring method of a rotary trash remover and a system for realizing the method.
Background
The main working structure of the rotary trash remover comprises a motor, a scraper bucket transmission shaft, a frame and the like. Under the drive of a motor, the scraper bucket rotates along the surface of the trash rack, and simultaneously brings dirt above the trash remover to be poured into the dirt discharge groove and conveyed away by the conveying mechanism. Various faults or even failure conditions can occur in the operation process of the rotary trash remover due to the reasons of complex structure, severe environment, inconvenient operation and maintenance and the like. The inventor analyzes that the rotary trash remover mainly faces the following problems in operation: (1) Tiny floating waterweeds and household garbage are easy to adsorb and wind on the trash rack and the toothed harrow, so that the speed of water flow entering the trash rack is reduced, a water level difference between the front and the back of the trash rack is generated, the water level of a water inlet pool is reduced, and the safe operation of a unit is influenced; (2) A safety pin is arranged between the motor of the trash remover and the chain wheel, when garbage and floating objects are accumulated too much, the safety pin is sheared to protect the motor from being damaged, but the safety pin has no safety early warning measure, cannot early warn, cannot accurately judge the shutdown time, and influences the engineering operation; (3) The untimely salvage of the aquatic weeds can cause that a large amount of aquatic weeds accumulated in front of the trash rack can cause poor flow state of the water inlet pool, so that the water pump is damaged by cavitation, and the trash rack is damaged by vibration; (4) A large amount of water plants accumulated in front of the trash rack can lift the water level in front of the trash rack, and the water pressure and deposited dirt increase the stress of the trash rack structure and threaten the operation safety of the trash remover.
In the prior art, the rotary trash remover is mainly monitored by manual inspection, however, the trash remover is complex in structure and short in downtime, and the maintainers cannot guarantee the comprehensive inspection of the trash remover, so that a fault point at a blind area becomes a hidden danger point of the whole device, and once the trash remover stops working due to faults, the water supply of a pump station cannot be guaranteed; in addition, the trash remover is mostly operated and controlled on site, the intelligent degree is low, the trash removing efficiency is influenced, and meanwhile, human resources are wasted.
Disclosure of Invention
The invention aims to provide an online monitoring method of a rotary trash remover, which aims to solve the technical problem that manual inspection is adopted for operation monitoring of the rotary trash remover in the prior art.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
an online monitoring method for a rotary trash remover comprises the following steps:
(1) Acquiring related data of the rotary trash remover in an operating state through a sensor;
(2) Processing data collected by the sensor;
(3) Generating a statistical curve and an operation report of online monitoring;
the type and the arrangement mode of the sensors in the step (1) are as follows:
the stress sensor is arranged at the position of a main beam of the rotary trash remover and is used for acquiring strain data of the main beam of the rotary trash remover;
the three-axis acceleration sensor is arranged on a main frame of the rotary type trash cleaning machine and is used for acquiring sinusoidal vibration and random vibration data of different positions on the main frame of the rotary type trash cleaning machine;
the acoustic emission sensor is arranged at a main shaft sleeve of the rotary trash remover and is used for acquiring ultrasonic data of friction between a main shaft and the sleeve of the rotary trash remover;
the pressure sensor is arranged on a chain wheel supporting seat of the rotary trash remover and used for acquiring pressure data of the chain wheel supporting seat;
the single-shaft acceleration sensor is arranged at the position of a motor of the rotary trash remover and is used for acquiring vibration data of the motor during operation;
and the torque sensor is arranged between the motor and the chain wheel of the rotary trash remover and is used for acquiring torque data between the chain wheel and the motor.
Preferably, the method further comprises the following steps of online monitoring:
(I) Monitoring the area of waterweeds in an upstream watershed of the rotary trash remover through video monitoring;
(II) judging whether the area of the waterweeds reaches a threshold value;
if yes, sending a control instruction to a trash remover control cabinet, and automatically opening the trash remover to remove trash; if not, returning to the step (II).
Preferably, the method for processing data in (2) includes: filtering, noise reduction, averaging, and/or regression.
Preferably, the specific method for judging whether the area of the aquatic weeds reaches the threshold value in the step (II) is as follows:
firstly, acquiring an image of an upstream drainage basin of a rotary trash remover, and performing filtering and noise reduction treatment on the image to obtain a primary treatment image;
secondly, performing image enhancement processing on the primary processed image to obtain a secondary processed image;
secondly, processing the secondary processed image based on a YOLO algorithm to obtain a tertiary processed image containing a float grass region;
and finally, calculating the area of the float grass region in the three-stage processed image, and judging whether the calculated area of the float grass region exceeds a set threshold value.
Preferably, the method further comprises the following steps of (4): if the online monitoring finds that the abnormality is found, early warning or alarm information is sent out.
In order to achieve the above object, the present invention further provides a system for implementing an online monitoring method for a rotary trash remover, comprising:
the data acquisition unit acquires the associated data of the rotary trash remover in the running state through the sensor;
the data processing unit is used for processing the data acquired by the sensor;
and the monitoring display unit is used for generating a statistical curve and an operation report of online monitoring.
Preferably, the data acquisition unit includes: the main bearing frame stress monitoring module is used for acquiring strain data of a main beam of the rotary type sewage cleaning machine;
the vibration response monitoring module is used for acquiring sinusoidal vibration and random vibration data of different positions on the main frame of the rotary dirt cleaning machine;
the main shaft sleeve abrasion monitoring module is used for acquiring ultrasonic data of friction between a main shaft and a sleeve of the rotary trash remover;
the driving chain tension monitoring module is used for acquiring pressure data of the chain wheel supporting seat;
the motor vibration monitoring module is used for acquiring vibration data when the motor runs;
and the motor safety pin monitoring module is used for acquiring torque data between the chain wheel and the motor.
Preferably, the system further comprises an online monitoring module for monitoring the waterweed area in the upstream drainage basin of the rotary trash remover.
Preferably, the automatic cleaning machine further comprises a control module for sending a control command to the cleaning machine control cabinet.
Preferably, the system also comprises an early warning module used for sending out early warning or warning information.
Compared with the prior art, the invention has the following beneficial effects:
(1) Through the analysis of the inventor on the operation of the rotary trash remover, based on the structural characteristics of the rotary trash remover and the problems faced by the operation of the rotary trash remover, the invention collects the operation related data of the trash remover by arranging sensors and corresponding arrangement points thereof around the operation of the rotary trash remover: strain data, sinusoidal vibration, random vibration data, ultrasonic data, pressure data, vibration data and torque data, and real-time online monitoring of static stress, dynamic stress, vibration response, motor running state and the like of the rotary type trash remover is realized, so that defects, safety fault phenomena and reasons can be accurately found and judged, regular manual inspection and conventional inspection instruments adopted in the prior art are replaced, new guarantee is provided for safe running of rotary type trash remover equipment, and the blank of real-time online monitoring of hydraulic and hydroelectric engineering metal structures (rotary type trash removers) in China is filled.
(2) The invention monitors the aquatic weed area of the upstream basin of the rotary trash remover based on video monitoring, can realize automatic start-stop of the trash remover by combining the monitoring result with the set threshold value, and effectively solves the problems that most trash removers in the prior art adopt local operation control, the intelligentization degree is low, the trash removal efficiency is influenced, and meanwhile, the human resource waste is caused.
Drawings
Fig. 1 is a first schematic flow chart of embodiment 1 of the present invention.
FIG. 2 is a second flow chart of example 1 of the present invention.
Fig. 3 is a third schematic flow chart of embodiment 1 of the present invention.
Fig. 4 is a diagram showing the distribution positions of the sensors in embodiment 1 of the present invention.
Fig. 5 is a schematic block diagram of embodiment 2 of the present invention.
Fig. 6 is a schematic block diagram of embodiment 3 of the present invention.
Wherein, the names corresponding to the reference numbers are as follows: the system comprises a stress sensor 1, a triaxial acceleration sensor 2, an acoustic emission sensor 3, a pressure sensor 4, a uniaxial acceleration sensor 5 and a torque sensor 6.
Detailed Description
In order that those skilled in the art will more clearly understand and appreciate the present invention, the following detailed description of the present invention is provided in conjunction with the examples. It should be understood that the following specific examples are only for illustrating the present invention, and it is convenient to understand that the technical solutions provided by the present invention are not limited to the technical solutions provided by the following examples, and the technical solutions provided by the examples should not limit the protection scope of the present invention.
Example 1
As shown in fig. 1 to 4, the present embodiment provides an online monitoring method for a rotary trash remover, which is proposed based on the analysis of the operation condition of the rotary trash remover (see background technology for details) by the inventor of the present invention, and combines the analysis result, and implements the acquisition of various associated data in the operation state of the rotary trash remover by arranging different types of sensors for the rotary trash remover, and implements the online monitoring of the rotary trash remover according to the acquired associated data. Specifically, the method mainly comprises the following steps:
1. acquisition of relevant data of rotary trash remover in running state through sensor
In this embodiment, the types of sensors, the arrangement and the functions thereof are as follows:
the stress sensor is arranged at the position of a main beam of the rotary trash remover and is used for acquiring strain data of the main beam of the rotary trash remover; preferably, the stress sensor is a waterproof digital strain sensor, and strain data are acquired by the strain gauge after the steel plate is stressed and deformed.
The three-axis acceleration sensor is arranged on a main frame of the rotary type trash cleaning machine and is used for acquiring sinusoidal vibration and random vibration data of different positions on the main frame of the rotary type trash cleaning machine; when the rotary trash remover is started and is impacted by water flow, the three-axis acceleration sensor acquires sinusoidal vibration and random vibration data at different positions, then the vibration data at different positions are transmitted to the processor, the processor performs post-processing such as filtering, noise removing, averaging, regression and the like according to the acquired data to obtain vibration measured values of each measuring point and each direction, and vibration displacement induced by water flow pulsation of the rotary trash remover under different operating conditions is calculated according to the measured values.
The acoustic emission sensor is arranged at a main shaft sleeve of the rotary trash remover and is used for acquiring ultrasonic data of friction between a main shaft and the sleeve of the rotary trash remover; the acoustic emission sensor collects ultrasonic data of a friction position, then the ultrasonic data are transmitted to the processor, the processor performs post-processing such as filtering, noise reduction, averaging, regression and the like according to the collected data to obtain a friction characteristic value of the friction pair, and the abrasion state of the sleeve is judged according to the characteristic value.
The pressure sensor is arranged on a chain wheel supporting seat of the rotary trash remover and used for acquiring pressure data of the chain wheel supporting seat; when the trash remover fills the filth, the chain can be tensioned, the weight of the filth is shared on the chain wheel supporting seats on the two sides, and the pressure sensor can acquire pressure data.
The single-shaft acceleration sensor is arranged at the position of a motor of the rotary trash remover and is used for collecting vibration data of the motor during operation; the vibration condition of the motor during operation is monitored through the single-shaft acceleration sensor, and the abnormal vibration condition is pre-warned.
The torque sensor is arranged between a motor and a chain wheel of the rotary trash remover and is used for acquiring torque data between the chain wheel and the motor; when the trash remover loads the filth, the moment of torsion between sprocket and the motor increases, and the corresponding increase of shear stress of safe round pin axle, torque sensor can gather the moment of torsion data.
2. Processing data collected by a sensor
The data collected by the sensors are transmitted to a local processor in a Modbus mode, the local processor performs filtering, noise reduction, averaging and/or regression on the collected data to obtain processed data, and the processed data are stored, analyzed, comprehensively evaluated and the like.
3. Generating on-line monitoring statistical curve and running report
And generating a statistical curve and an operation report of online monitoring according to the processed data, and displaying an online monitoring result in a line graph and report form, so that a worker can observe the online monitoring result more visually.
4. Early warning or alarming: if the online monitoring finds that the abnormality is found, early warning or alarm information is sent out.
In further preferred scheme, for solving current rotation trash cleaning machine and opening and stop the not enough of operation and rely on manual operation basically, improve the intellectuality of rotation trash cleaning machine control, this embodiment still provides on-line monitoring, and it mainly includes:
(I) The method comprises the steps of monitoring the area of waterweeds in an upstream drainage basin of the rotary trash remover through video monitoring, and acquiring a monitoring picture of the upstream drainage basin of the rotary trash remover through front-end camera shooting by the video monitoring.
(II) judging whether the area of the aquatic weeds reaches a threshold value; in this embodiment, a specific method for determining whether the area of the aquatic weeds reaches the threshold value is as follows: firstly, acquiring an image of an upstream drainage basin of a rotary trash remover, and performing filtering and noise reduction processing on the image to obtain a primary processing image; secondly, performing image enhancement processing on the primary processed image to obtain a secondary processed image, wherein the gray value of a water grass containing area in the primary processed image is larger than that of a non-water grass containing area; secondly, processing the secondary processed image based on a YOLO algorithm to obtain a tertiary processed image containing a waterweed area; and finally, calculating the area of the float grass region in the three-stage processing image, and judging whether the calculated area of the float grass region exceeds a set threshold value, wherein the set threshold value is a value set by a worker according to parameters such as the model and the power of the rotary trash remover.
If yes, sending a control instruction to the trash remover control cabinet, automatically opening the trash remover to remove trash, sending the control instruction to the trash remover control cabinet after the trash removal is finished, and automatically closing the trash remover; if not, returning to the step (II).
By the method, the waterweed area of the upstream water area of the rotary type trash remover is monitored, and the rotary type trash remover is controlled according to the monitoring result, so that the rotary type trash remover is automatically started and stopped, and the defects in the prior art are overcome.
Example 2
As shown in fig. 5, this embodiment provides a system for implementing the online monitoring method of the rotary trash remover described in embodiment 1, that is, an online monitoring system of the rotary trash remover, where the system includes a data acquisition unit for acquiring relevant data of the rotary trash remover in an operating state by using a sensor; the data processing unit is used for processing the data acquired by the sensor; and the monitoring display unit is used for generating a statistical curve and an operation report of online monitoring. The data processing unit adopts a local processor, and the functions of the monitoring display unit can be combined with the data processing unit and are uniformly realized by the local hardware processor.
In this embodiment, the data acquisition unit specifically includes the following modules: the main bearing frame stress monitoring module is used for acquiring strain data of a main beam of the rotary type sewage cleaning machine, and adopts a sensor as a stress sensor; the vibration response monitoring module is used for acquiring sinusoidal vibration and random vibration data of different positions on the main frame of the rotary type sewage cleaning machine, and adopts a sensor as a three-axis acceleration sensor; the main shaft sleeve abrasion monitoring module is used for acquiring ultrasonic data of friction between a main shaft and a sleeve of the rotary trash remover, and adopts a sensor as an acoustic emission sensor; the driving chain tension monitoring module is used for acquiring pressure data of the chain wheel supporting seat, and a sensor is used as a pressure sensor; the motor vibration monitoring module is used for collecting vibration data when the motor runs and adopts a single-shaft acceleration sensor as a sensor; and the motor safety pin monitoring module is used for acquiring torque data between the chain wheel and the motor, and adopts a sensor as a torque sensor.
In a further preferred scheme, the system further comprises an early warning module for sending early warning or warning information, and the early warning module realizes early warning or warning according to the result of online monitoring under the condition that the monitoring data is abnormal.
In a further preferred scheme, the system further comprises an online monitoring module and a control module, wherein the online monitoring module is used for monitoring the aquatic weed area of the upstream drainage basin of the rotary type trash remover. The online monitoring module acquires a video image of an upstream drainage basin of the rotary trash remover through the front-end camera, and then sends a control instruction to the trash remover control cabinet by combining the control module according to the area of aquatic weeds in the video image, so that the automatic start-stop control of the rotary trash remover is realized.
Example 3
Generally, the rotary trash cleaners arranged at one pump station are not only one but also multiple, for example: the precious 10 inlet openings of the current trash remover of pump station of answering are provided with 10 tooth harrow rotary trash removers, and the clear width in drill way 4m, bars inclination 75, grid interval 110mm, the design head is poor 1.5m, current trash remover switch board 10.
As shown in fig. 6, in order to adapt to the control of multiple rotary trash cleaners, this embodiment provides a centralized monitoring system for rotary trash cleaners, which includes several systems described in embodiment 2 (online monitoring systems for rotary trash cleaners), and each rotary trash cleaner is matched with one system described in embodiment 2 and shares one online monitoring module and one control module.
The centralized monitoring system of the rotary trash remover can start and stop a plurality of trash removers simultaneously, can intensively display signals such as loads, vibration, water level difference and video of the trash removers, and can realize 24-hour online monitoring and automatic control of all equipment of a pump station by combining the centralized monitoring system of the rotary trash remover with a trash remover control cabinet.
The above description is the preferred embodiment of the present invention. It should be noted that, the skilled in the art can make several modifications without departing from the design principle and technical scheme of the present invention, and these modifications should also be regarded as the protection scope of the present invention.
Claims (10)
1. An online monitoring method for a rotary trash remover is characterized by comprising the following steps:
(1) Acquiring related data of the rotary trash remover in an operating state through a sensor;
(2) Processing data collected by the sensor;
(3) Generating a statistical curve and an operation report of online monitoring;
the type and the arrangement mode of the sensor in the step (1) are as follows:
the stress sensor is arranged at the position of a main beam of the rotary type trash remover and is used for acquiring strain data of the main beam of the rotary type trash remover;
the three-axis acceleration sensor is arranged on a main frame of the rotary type trash cleaning machine and is used for acquiring sinusoidal vibration and random vibration data of different positions on the main frame of the rotary type trash cleaning machine;
the acoustic emission sensor is arranged at a main shaft sleeve of the rotary trash remover and is used for acquiring ultrasonic data of friction between a main shaft and the sleeve of the rotary trash remover;
the pressure sensor is arranged on a chain wheel supporting seat of the rotary trash remover and used for acquiring pressure data of the chain wheel supporting seat;
the single-shaft acceleration sensor is arranged at the position of a motor of the rotary trash remover and is used for acquiring vibration data of the motor during operation;
and the torque sensor is arranged between the motor and the chain wheel of the rotary trash remover and is used for acquiring torque data between the chain wheel and the motor.
2. The rotary trash remover on-line monitoring method as claimed in claim 1, further comprising on-line monitoring:
(I) Monitoring the area of waterweeds in an upstream watershed of the rotary trash remover through video monitoring;
(II) judging whether the area of the aquatic weeds reaches a threshold value;
(III) if so, sending a control instruction to a trash remover control cabinet, and automatically opening the trash remover to remove trash; if not, returning to the step (II).
3. The rotary trash remover on-line monitoring method as claimed in claim 2, wherein the data processing method in (2) comprises: filtering, noise reduction, averaging, and/or regression.
4. The rotary trash remover on-line monitoring method as claimed in claim 3, wherein the specific method for determining whether the area of the aquatic weeds reaches the threshold value in (II) is as follows:
firstly, acquiring an image of an upstream drainage basin of a rotary trash remover, and performing filtering and noise reduction processing on the image to obtain a primary processing image;
secondly, performing image enhancement processing on the primary processed image to obtain a secondary processed image;
secondly, processing the secondary processed image based on a YOLO algorithm to obtain a tertiary processed image containing a waterweed area;
and finally, calculating the area of the float grass region in the three-stage processing image, and judging whether the calculated area of the float grass region exceeds a set threshold value.
5. The rotary trash remover on-line monitoring method of claim 4, further comprising (4): if the online monitoring finds that the system is abnormal, early warning or alarm information is sent out.
6. The system for realizing the online monitoring method of the rotary type trash remover as claimed in any one of claims 1 to 5, comprising:
the data acquisition unit acquires the associated data of the rotary trash remover in the running state through the sensor;
the data processing unit is used for processing the data acquired by the sensor;
and the monitoring display unit is used for generating a statistical curve and an operation report of online monitoring.
7. The system of claim 6, wherein the data acquisition unit comprises: the main bearing frame stress monitoring module is used for acquiring strain data of a main beam of the rotary type sewage cleaning machine;
the vibration response monitoring module is used for acquiring sinusoidal vibration and random vibration data of different positions on the main frame of the rotary dirt cleaning machine;
the main shaft sleeve abrasion monitoring module is used for acquiring ultrasonic data of friction between a main shaft and a sleeve of the rotary trash remover;
the driving chain tension monitoring module is used for acquiring pressure data of the chain wheel supporting seat;
the motor vibration monitoring module is used for acquiring vibration data when the motor runs;
and the motor safety pin monitoring module is used for acquiring torque data between the chain wheel and the motor.
8. The system of claim 7, further comprising an online monitoring module for monitoring the waterweed area upstream of the rotary scarifier.
9. The system of claim 8, further comprising a control module for issuing control instructions to the purge machine control cabinet.
10. The system of claim 8, further comprising an early warning module for issuing early warning or alert information.
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| 卜贵贤: "水利工程管理", 黄河水利出版社, pages: 188 - 189 * |
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