CN210133831U - Safety monitoring system for mast crane - Google Patents
Safety monitoring system for mast crane Download PDFInfo
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- CN210133831U CN210133831U CN201920610583.8U CN201920610583U CN210133831U CN 210133831 U CN210133831 U CN 210133831U CN 201920610583 U CN201920610583 U CN 201920610583U CN 210133831 U CN210133831 U CN 210133831U
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Abstract
The utility model discloses a mast crane safety monitoring system, including state acquisition module, parameter acquisition module, stress acquisition module, video acquisition module, signal relay processor and safety management module, state acquisition module, parameter acquisition module and stress acquisition module transmit the data transmission of gathering separately for signal relay processor, signal relay processor sends the back with signal processing and gives safety management module, video acquisition module transmits the data transmission of gathering for safety management module, safety management module carries out data management and common fault's logical judgement to the data that signal relay processor and video acquisition module transmission come, and show on the touch-sensitive screen. The system has the functions of monitoring the operation parameters and the operation state of the mast crane, monitoring the structural stress, monitoring the lifting hook video and pre-warning the main fault of the crane, and can realize the safety management of the daily operation of the mast crane.
Description
Technical Field
The utility model relates to a mast crane safety technical field, concretely relates to mast crane safety monitoring system.
Background
The crane as an electromechanical device mainly comprises a structure, a mechanism, an electric and safety protection device and the like, and the crane inevitably has faults in use. Some faults can have great influence on the crane, and if the faults cannot be eliminated in time, once danger occurs, serious consequences or even disastrous accidents can be caused. The crane is always used as one of eight types of special equipment to be subjected to key supervision by the country.
At present, the most common inspection for the service condition of the crane is daily inspection, the daily inspection is generally periodic inspection performed by a person specially assigned to a service unit according to time nodes, inspection contents mainly aim at appearance inspection of the running state of the crane, but the actual running condition and potential safety hazard of the crane are difficult to accurately judge through the inspection based on visual inspection and experience, and the daily management and maintenance management of the crane at present have certain blindness. Therefore, the running parameters and the running state of the crane, especially key running data, need to be acquired in real time through technical means, a reliable data source is provided for daily management of a crane user, the fault rate of equipment can be effectively reduced through the method, and the supervision technology and means of the crane are promoted.
The mast type crane is a moving arm type crane taking a mast as a machine body, the main structure is a single mast or double masts, the masts play double roles of supporting and amplitude changing, other boom structures are not arranged in the whole structure, the bottom end of the mast is hinged on a base, and the top is connected to a ground anchor from one or more directions by cables. The crane has the characteristics of simple overall structure, light dead weight, stable work, large load and the like, and is generally used for port and wharf ship unloading and large-scale hoisting equipment. Generally speaking, the mast crane has a large lifting capacity and a certain danger in operation, and the national relevant safety specifications require that a safety monitoring system should be installed on a mast crane exceeding 100 tons.
Due to the structural and structural particularity of the mast crane, the condition that data monitoring is incomplete and inaccurate exists in parameter monitoring at present. A lifting steel wire rope drum of the mast type crane is arranged on the ground, and a steel wire rope winding system is obliquely pulled from the ground to lift heavy objects after passing through a fixed pulley at the top of the mast, so that the traditional method of collecting lifting capacity parameters by adopting a side-pressure type or bearing seat type sensor cannot accurately acquire the load capacity of the crane.
Disclosure of Invention
The utility model aims at providing a mast crane safety monitoring system solves among the prior art and has the not comprehensive and unsafe technical problem of data monitoring to mast crane parameter monitoring.
In order to solve the technical problem, the utility model discloses a following technical scheme:
a safety monitoring system of a mast crane comprises a state acquisition module, a parameter acquisition module, a stress acquisition module, a video acquisition module, a signal relay processor and a safety management module, wherein the state acquisition module, the parameter acquisition module and the stress acquisition module transmit respectively acquired data to the signal relay processor, the signal relay processor processes the signals and then sends the processed signals to the safety management module, the video acquisition module transmits the acquired data to the safety management module, and the safety management module performs data management and logic judgment of common faults on the data transmitted by the signal relay processor and the video acquisition module and displays the data on a display.
The system is further improved in that the state acquisition module comprises auxiliary contacts of a plurality of contactors connected into a control circuit in an electric control cabinet of the crane, the auxiliary contacts respectively acquire the on-off state of a load lifting limiter, the on-off state of a height limiter, the on-off state of an amplitude limiter, the on-off state of a device for preventing the arm frame from tipping backwards, the on-off state of a main power supply and the on-off state of an emergency stop device, an on-off state signal of each auxiliary contact is isolated by an optical coupler and converted into a digital quantity, the digital quantity is transmitted to the STC single chip microcomputer, and the STC single chip microcomputer is connected with 433 a wireless communication module through an asynchronous serial communication interface and transmits each acquired.
The system parameter acquisition module comprises a current sensor arranged on a power supply line of a motor of a lifting mechanism of the mast crane, and the lifting capacity of the crane is acquired by adopting a current method; the absolute value rotary encoder is arranged at a reel bearing of the hoisting mechanism and is used for acquiring the hoisting height; the method comprises the following steps that an inclination angle sensor arranged at the root of a mast is used for collecting an arm support inclination angle of a crane, the amplitude of the crane is obtained through calculation of the arm support inclination angle and the arm support length, and a specific numerical value of a lifting moment is obtained through calculation of measured lifting capacity and amplitude data; a wind speed sensor arranged on the top of the mast collects a wind speed value; a signal acquisition device arranged in the control cabinet extracts an operation instruction, and calculates the action time of each mechanism of the crane, so as to obtain the working time, the accumulated working time and the working cycle of the crane; obtaining a vibration value of a reduction gearbox through an absolute value acceleration sensor arranged on the reduction gearbox of the hoisting mechanism;
the current sensor, the absolute value rotary encoder, the tilt angle sensor, the wind speed sensor, the signal acquisition device and the absolute value acceleration sensor are all electrically connected with the RS485 interface, the RS485 interface is communicated with the STC single chip microcomputer through MAX3082, and the STC single chip microcomputer forwards data to the signal relay processor for centralized processing through the 433 wireless communication module.
The structural stress acquisition module comprises a strain gauge and a strain data acquisition unit, and the strain gauge is connected with the strain data acquisition unit through a lead;
the strain gauge is a resistance-type surface strain gauge and is adhered to a stress concentration area of the mast structure; when the crane load changes, the resistance of the strain gauge changes, continuously changing voltage data are output, and after data conversion of the strain collector, the continuously changing voltage data are uploaded to the safety management module in a wireless WIFI mode to be displayed and stored.
In a further improvement, the video acquisition module comprises a plurality of cameras which can clearly see the full operation range of the lifting hook; the image data shot by each camera is transmitted to the switch in a centralized mode through the super-five network cables, the switch transmits the image data to the hard disk recorder through the super-five network cables, the data are stored in the hard disk, and the hard disk recorder transmits the data to the display of the safety management module through the VGA data cable for display.
In a further improvement, the video acquisition module comprises two wide-angle cameras arranged in the middle and at the top of the mast.
The safety management module comprises a controller and a display installed in a crane control room, the controller is electrically connected with the display, the controller processes and displays received data, stores the received data, gives an alarm for potential faults and backtracks historical data, and the display is used for displaying video monitoring pictures, acquired parameter values and various state quantities in real time.
The safety management module is a tablet personal computer, so that the safety management module is small in size and convenient to carry.
The utility model has the advantages that:
1. the system has the function of multi-state and multi-parameter acquisition of the crane, can realize all the running parameters and states required by the daily safety management of the crane, and has accurate and reliable measuring results.
2. The lifting capacity of the mast crane is acquired by adopting a current method, and the data is accurate and reliable.
3. The system is convenient to install, and the structure and the control system of the original mast crane are not damaged.
4. The system safety management module can perform early warning on common electrical and mechanical faults of the crane.
Drawings
FIG. 1 is a diagram of a mast crane safety monitoring system.
Fig. 2 is a circuit diagram of a signal relay processor.
Fig. 3 is a state acquisition module architecture diagram.
Fig. 4 is a circuit diagram of a state acquisition module.
FIG. 5 is a system parameter acquisition module architecture.
Fig. 6 is a circuit diagram of a hoist height data acquisition circuit.
Fig. 7 is a circuit diagram of amplitude data acquisition.
FIG. 8 is a circuit diagram of wind speed data acquisition.
FIG. 9 is a circuit diagram of load lifting data acquisition.
Fig. 10 is a circuit diagram of a strain data collector.
Fig. 11 is a schematic view of a video capture module.
Fig. 12 is a security management module architecture diagram.
Detailed Description
For better understanding of the present invention, the following examples are provided to further illustrate the present invention, but the present invention is not limited to the following examples.
As shown in figure 1, mast crane safety monitoring system, including state collection module, parameter acquisition module, stress acquisition module, video acquisition module, signal relay processor and safety management module, state collection module, parameter acquisition module and stress acquisition module transmit the data transmission of gathering separately for signal relay processor, video acquisition module transmits the data transmission of gathering for signal relay processor, signal relay processor sends the back with signal processing for safety management module, safety management module integrates the data that signal relay processor and video acquisition module transmitted, carry out data management and common fault's logical judgement, and show on the touch-sensitive screen.
The circuit of the signal relay processor is shown in fig. 2, data acquired by the state acquisition module, the parameter acquisition module and the stress acquisition module are transmitted to the signal relay processor in a wireless mode, and the data are displayed on a human-computer interface after being summarized and processed by the signal relay processor. The circuit comprises an embedded MCU minimum system, an RS485 communication circuit, an RS232 communication circuit, a JTAG debugging interface, a power supply circuit, a reset circuit and an indication circuit.
The system state acquisition module is configured as shown in fig. 3, and acquires the on-off state of the lifting capacity limiter, the on-off state of the height limiter, the on-off state of the amplitude limiter, the on-off state of the device for preventing the arm frame from tipping backwards, the on-off state of the main power supply, the on-off state of the emergency stop device and other state quantities through a switching quantity acquisition device installed in an electric control cabinet of the crane.
The state acquisition module circuit is shown in fig. 4, specifically, the auxiliary contacts of the crane control circuit contactor are used for acquiring the opening and closing states of the height limiter, the backward tilting prevention device, the emergency stop device, the main power supply and the lifting load limiter, the opening and closing states of the auxiliary contacts are isolated by the optical coupler and converted into digital quantity to be transmitted to the STC single chip microcomputer, and the STC single chip microcomputer transmits the acquired switching quantities to the signal relay module for centralized processing through the asynchronous serial communication interface connection 433 wireless communication module.
The system parameter acquisition module is configured as shown in fig. 5, and the following modes are respectively adopted for the acquisition of various crane parameters: the hoisting capacity of the crane is obtained by adopting a current method through a current sensor arranged on a power supply line of a motor of the hoisting mechanism; the lifting height is collected through an absolute value rotary encoder (a sensor GMS412RE10PB-9) arranged at a reel bearing of the lifting mechanism; acquiring an arm support inclination angle of the crane through an inclination angle sensor arranged at the root of a mast; calculating the amplitude of the crane according to the inclination angle of the arm support and the length of the arm support; calculating to obtain a specific numerical value of the lifting moment through the measured lifting capacity and amplitude data; acquiring a wind speed value through an anemometer arranged on the top of the mast; extracting an operation instruction through a signal acquisition device additionally arranged in the control cabinet, and calculating the action time of each mechanism of the crane so as to obtain the working time, the accumulated working time and the working cycle of the crane through calculation; the vibration value of the reduction gearbox is obtained through an absolute value acceleration sensor arranged on the reduction gearbox of the hoisting mechanism.
An absolute value rotary encoder (a sensor GMS412RE10PB-9) is installed at a ground winding drum of the mast crane and rotates synchronously with the winding drum, the rotary encoder outputs an RS485 digital signal, the RS485 digital signal is transmitted to an STC single chip microcomputer through MAX3082, and then the signal is transmitted to a signal relay module through a 433 wireless communication module by the STC single chip microcomputer. As shown in fig. 6.
An inclination angle sensor (sensor JD-180) is installed at the root of the main arm of the mast crane, the sensor outputs an RS485 digital signal, the RS485 digital signal is transmitted to an STC single-chip microcomputer through MAX3082, the length of the main arm is fixed and is converted through a trigonometric function to obtain an amplitude value through calculation, and then the amplitude value is transmitted to a signal relay module through a 433 wireless communication module by the STC single-chip microcomputer. As shown in fig. 7.
The wind speed sensor (sensor WFS-1) is arranged at the top of a main arm of the mast crane, the sensor outputs an RS485 digital signal, the digital signal is transmitted to the STC single chip microcomputer through MAX3082, and then the digital signal is transmitted to the signal relay module through the wireless communication module 433 by the STC single chip microcomputer. As shown in fig. 8.
The current transformer (the sensor KXT-10I) is shown in the figure, collects the running current value of the lifting motor, outputs 4-20mA current signals, is converted by the circuit, outputs 0-5V analog voltage data, is converted into digital signals by the STC singlechip analog-digital module, and transmits the data to the signal relay processor by the wireless communication module. As shown in fig. 9.
The structural stress acquisition module adopts a strain electrical measurement method to monitor stress, and because the mast crane is installed outdoors, the working environment is generally severe and humid, and the stress acquisition needs to be monitored for a long time, a resistance type surface strain gauge is selected and used to be installed in a sticking mode. The system is characterized in that the mast structure of the mast crane is large in size, stress data transmission is carried out in a wireless data transmission mode, the strain gauge adopts a resistance type surface strain gauge DH1205, the resistance type surface strain gauge DH1205 is pasted in a stress concentration area of the mast structure and is connected to a strain data collector, when the load of the crane changes, the resistance of the strain gauge changes, continuously changing voltage data are output outwards, the voltage data are uploaded to a local terminal in an operating room in a wireless WIFI mode after data conversion of the strain data collector, and the voltage data are displayed and stored in a safety management module.
The strain data acquisition module is developed based on a PS021 chip of the Germany ACAM company as shown in FIG. 10. The chip is a strain measurement digital chip developed based on a TDC (time-to-digital conversion) technology, and has very high measurement flexibility. The voltage signal obtained from the strain gauge is converted into a digital signal by the module. The peripheral circuit of the PS021 chip can be externally connected with 2 full bridges or 4 half bridges at most, and is provided with an independent temperature measurement module, and the temperature drift and the zero drift are compensated in the external circuit respectively. The system adopts a full-bridge connection method, the two full bridges work independently, and the working stress of two measuring points can be measured respectively.
The video acquisition module uses a camera (the model is DS-2CD3T56WD-I3), is installed at the top end of a main arm to acquire images, and transmits a plurality of image data to the switch (the model is TL-SG1008M) in a centralized manner by using a super-five network cable, the switch transmits the image data to the hard disk recorder (the model is DS-7104N-F1) by using the super-five network cable, the data is stored in the hard disk (the model is ST2000DM006), and the hard disk recorder transmits the data to the display screen (the model is AOC22B1HS) by using the VGA data cable. As shown in fig. 11.
The security management module architecture is shown in fig. 12. The module is mainly used by crane operators, the terminal display is arranged in a crane operating room, and the module has an intuitive interface and stronger transaction processing capability, and has the functions of data receiving and analyzing, data processing and displaying, data storing, potential fault alarming, historical data backtracking, data uploading, video monitoring and the like.
The specific installation mode of the system is as follows: installing current sensors at corresponding positions in the control cabinet, and monitoring the current value of the lifting motor; an inclination angle sensor (the model is JD-180) is additionally arranged at the bottom of the mast to monitor the real-time angle of the crane; a rotary encoder is additionally arranged at a reel bearing of the hoisting mechanism; a wind speed sensor (model is WFS-1 wind speed sensor) is arranged at the top of the mast; a signal acquisition device is additionally arranged in an electric control cabinet of the crane to extract an operation instruction. All kinds of sensors installed additional transmit the data that its was gathered for signal relay processor, and signal relay processor converts the signal conversion who gathers into digital signal, and the monitored control system of being convenient for handles and stores, handles the back and sends in unison for safety control module, and this signal supports RS485 output, at 2 wide angle cameras of mast middle part and top installation, guarantees to see the full operating range of lifting hook clearly, and this signal direct transmission is to safety control module. An industrial touch panel display screen is additionally arranged in the control room to serve as a display of the system, and various data and functions of the safety management module are displayed on the display
What has not been described in detail in the present invention is the prior art or can be realized by the prior art, and the specific embodiment of the present invention is only the preferred embodiment of the present invention, which is not intended to limit the scope of the present invention. All equivalent changes and modifications made according to the content of the claims of the present invention should be regarded as the technical scope of the present invention.
Claims (8)
1. A safety monitoring system of a mast crane is characterized by comprising a state acquisition module, a parameter acquisition module, a stress acquisition module, a video acquisition module, a signal relay processor and a safety management module, wherein the state acquisition module, the parameter acquisition module and the stress acquisition module transmit respectively acquired data to the signal relay processor, the signal relay processor processes the signals and then sends the processed signals to the safety management module, the video acquisition module transmits the acquired data to the safety management module, and the safety management module performs data management and logic judgment of common faults on the data transmitted by the signal relay processor and the video acquisition module and displays the data on a display.
2. The mast crane safety monitoring system of claim 1, wherein the state acquisition module comprises a plurality of auxiliary contacts of contactors connected to a control circuit in an electric cabinet of the crane, the plurality of auxiliary contacts respectively acquire a load lifting limiter on-off state, a height limiter on-off state, an amplitude limiter on-off state, a boom tip-back prevention device on-off state, a main power supply on-off state and an emergency stop device on-off state, an on-off state signal of each auxiliary contact is isolated by an optical coupler, converted into a digital quantity and transmitted to the STC single chip microcomputer, and the STC single chip microcomputer transmits the acquired switching quantities to the signal relay processor for centralized processing through the asynchronous serial communication interface connection 433 wireless communication module.
3. The mast crane safety monitoring system of claim 2, wherein the parameter acquisition module comprises a current sensor arranged on a power supply line of a motor of a lifting mechanism of the mast crane, an absolute value rotary encoder arranged at a reel bearing of the lifting mechanism, an inclination angle sensor arranged at the root of the mast, an air speed sensor arranged at the top of the mast for acquiring an air speed value, a signal acquisition device arranged in a control cabinet and an absolute value acceleration sensor arranged on a reduction gearbox of the lifting mechanism;
the current sensor, the absolute value rotary encoder, the tilt angle sensor, the wind speed sensor, the signal acquisition device and the absolute value acceleration sensor are all electrically connected with the RS485 interface, the RS485 interface is communicated with the STC single chip microcomputer through MAX3082, and the STC single chip microcomputer forwards data to the signal relay processor for centralized processing through the 433 wireless communication module.
4. The mast crane safety monitoring system of claim 3, wherein the stress acquisition module comprises a strain gauge and a strain data acquisition unit, and the strain gauge and the strain data acquisition unit are connected through a wire;
the strain gauge is a resistance-type surface strain gauge and is adhered to a stress concentration area of the mast structure; when the crane load changes, the resistance of the strain gauge changes, continuously changing voltage data are output, and after data conversion of the strain collector, the continuously changing voltage data are uploaded to the safety management module in a wireless WIFI mode to be displayed and stored.
5. The mast crane safety monitoring system of claim 4, wherein the video capture module comprises a plurality of cameras configured to clearly see the full range of operation of the hook; the image data shot by each camera is transmitted to the switch in a centralized mode through the super-five network cables, the switch transmits the image data to the hard disk recorder through the super-five network cables, the data are stored in the hard disk, and the hard disk recorder transmits the data to the display of the safety management module through the VGA data cable for display.
6. The mast crane safety monitoring system of claim 5, wherein the video capture module comprises two wide angle cameras mounted at the middle and top of the mast.
7. The mast crane safety monitoring system of any one of claims 1 to 6, wherein the safety management module comprises a controller and a display installed in a crane control room, the controller is electrically connected with the display, the controller processes and displays received data, saves the received data, alarms potential faults and backtracks historical data, and the display is used for displaying video monitoring pictures, acquired parameter values and various state quantities in real time.
8. The mast crane security monitoring system of claim 7, wherein the security management module is a tablet computer.
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| CN201920610583.8U CN210133831U (en) | 2019-04-29 | 2019-04-29 | Safety monitoring system for mast crane |
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| CN201920610583.8U CN210133831U (en) | 2019-04-29 | 2019-04-29 | Safety monitoring system for mast crane |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116730226A (en) * | 2023-08-16 | 2023-09-12 | 新疆塔林投资(集团)有限责任公司 | Safety intelligent supervision system and method for cantilever crane |
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2019
- 2019-04-29 CN CN201920610583.8U patent/CN210133831U/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116730226A (en) * | 2023-08-16 | 2023-09-12 | 新疆塔林投资(集团)有限责任公司 | Safety intelligent supervision system and method for cantilever crane |
| CN116730226B (en) * | 2023-08-16 | 2023-10-27 | 新疆塔林投资(集团)有限责任公司 | Safety intelligent supervision system and method for cantilever crane |
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