CN116081481A - Portal crane running state monitoring method and monitoring system - Google Patents
Portal crane running state monitoring method and monitoring system Download PDFInfo
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- CN116081481A CN116081481A CN202211740749.0A CN202211740749A CN116081481A CN 116081481 A CN116081481 A CN 116081481A CN 202211740749 A CN202211740749 A CN 202211740749A CN 116081481 A CN116081481 A CN 116081481A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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- 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
- B66C15/06—Arrangements or use of warning devices
- B66C15/065—Arrangements or use of warning devices electrical
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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
- B66C19/00—Cranes comprising trolleys or crabs running on fixed or movable bridges or gantries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The application discloses a method and a system for monitoring the running state of a gantry crane, wherein the method comprises the steps of obtaining loaded data, stress data and mid-span deflection of a beam of the gantry crane; determining the maximum combined stress of the beam units of the gantry crane and the displacement value of the nodes of the beam units according to the loaded data; carrying out early warning on the running state of the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, and the maximum combined stress and displacement value; generating a maximum combined stress cloud picture according to the maximum combined stress, generating a gantry crane deformation cloud picture according to the displacement value, displaying the maximum combined stress cloud picture and the gantry crane deformation cloud picture on a three-dimensional model of the gantry crane, and displaying loaded data and information of running state early warning. The comprehensive monitoring of the gantry crane state is realized, the comprehensiveness and reliability of the gantry crane running state early warning are improved, and the running state of the gantry crane can be displayed more intuitively through various information visualizations.
Description
Technical Field
The application relates to the technical field of equipment health monitoring, in particular to a monitoring method and a monitoring system for the running state of a gantry crane.
Background
Large-scale hoisting mechanical equipment (gantry crane, bridge girder erection machine, cradle and the like) is an indispensable mechanical equipment in bridge construction, and is an operation platform for bridge constructors and machines. In the bridge construction process, all loads such as constructors, machines and tools, the weight of the beam Duan Hunning soil and the like are borne by large-scale hoisting equipment, and the safety of the constructors, the machines and the bridge structure can be ensured only by ensuring the stability and the safety of the large-scale hoisting equipment. Therefore, early warning is needed in the operation process of the hoisting mechanical equipment when the running state, the working state and the structural state of the hoisting mechanical equipment are abnormal, and safety personnel and operators are prompted to take countermeasures so as to ensure the safety of the mechanical equipment, the bridge structure and constructors.
In the related art, when monitoring the state of large hoisting equipment such as a gantry crane, whether early warning is performed is judged only by sensor data arranged at key stress parts of the gantry crane equipment, the problem that early warning stress measuring points are insufficient and incomplete exists, and damage of partial stress or deformation sensors has decisive influence on early warning reliability, so that the early warning reliability is low.
Therefore, how to comprehensively monitor the state of the gantry crane and improve the reliability of safety precaution is a technical problem to be solved.
Disclosure of Invention
The main aim of the application is to provide a monitoring method and a monitoring system for the running state of a gantry crane, which aim at solving the technical problems that whether the state monitoring point of the gantry crane is insufficient and not comprehensive is caused by judging whether to early warn only through sensor data arranged at the key stress part of the gantry crane equipment in the prior art.
In a first aspect, the present application provides a method for monitoring an operational state of a gantry crane, the method comprising the steps of:
acquiring loading data, stress data and cross beam mid-span deflection of the gantry crane;
determining the maximum combined stress of a beam unit of the gantry crane and the displacement value of a node of the beam unit according to the loaded data;
performing running state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value;
generating a maximum combined stress cloud picture according to the maximum combined stress, generating a gantry crane deformation cloud picture according to the displacement value, displaying the maximum combined stress cloud picture and the gantry crane deformation cloud picture on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information.
In some embodiments, the acquiring load data, stress data, and beam mid-span deflection of the gantry crane includes:
monitoring a load value of the gantry crane through a side pressure tension sensor arranged on a lifting hook of the gantry crane, and monitoring a loaded position of the gantry crane through a photoelectric encoder arranged on a crown block of the gantry crane;
monitoring the stress data through surface strain gauges respectively arranged at the cross beam midspan position of the gantry crane and the middle part of the supporting leg;
and monitoring the beam midspan deflection through a static level gauge respectively arranged at the leftmost end of the beam of the gantry crane and the midspan position of the beam.
In some embodiments, the determining the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit according to the loaded data includes:
applying load and boundary conditions to a preset gantry crane finite element model according to the load value and the loaded position;
calculating and obtaining the intra-unit force of the beam unit and the displacement value of the node of the beam unit through the gantry crane finite element model;
calculating and obtaining the maximum combined stress of the beam unit according to the intra-unit force of the beam unit;
Wherein the in-cell forces of the beam cell include axial forces, bending moments and shear forces.
In some embodiments, the performing the operation state early warning of the gantry crane according to the load data, the stress data, the beam mid-span deflection, the maximum combined stress and the displacement value includes:
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding first threshold values, a first-level early warning signal is sent to perform first-level running state early warning;
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding second threshold values, a secondary early warning signal is sent to perform secondary running state early warning;
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding third threshold values, a three-level early warning signal is sent to perform three-level operation state early warning;
wherein the third threshold is greater than the second threshold, the second threshold being greater than the first threshold.
In some embodiments, after the primary warning signal, the secondary warning signal or the tripolar warning signal is turned off, if the operation state warning level is increased, a warning signal of a corresponding level is sent out, if the operation state warning level is the same or is decreased, no warning signal is sent out any more, and information of operation state warning is stored.
In some embodiments, the method further comprises:
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain first thresholds respectively corresponding to the stress data and the cross beam midspan deflection;
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain second thresholds respectively corresponding to the stress data and the cross beam midspan deflection;
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load of the gantry crane into a preset gantry crane finite element model to obtain third thresholds respectively corresponding to the stress data and the cross beam midspan deflection.
In some embodiments, the method further comprises: determining whether a third threshold value of the beam mid-span deflection corresponding to the obtained beam mid-span deflection is larger than a preset beam mid-span deflection limit threshold value;
if yes, taking a cross beam mid-span deflection limit threshold value of a fourth preset multiple as a cross beam mid-span deflection first threshold value, taking a cross beam mid-span deflection limit threshold value of a fifth preset multiple as a cross beam mid-span deflection second threshold value, and taking the cross beam mid-span deflection limit threshold value as a cross beam mid-span deflection third threshold value, wherein the fifth preset multiple is larger than the fourth preset multiple;
wherein, the value of the cross beam mid-span deflection limit threshold is as follows:
f is the cross beam mid-span deflection limit threshold, S is the span of the gantry crane, and C is a constant parameter, wherein the constant parameter is valued according to the positioning accuracy of the gantry crane.
In a second aspect, the present application further provides a monitoring system for an operating state of a gantry crane, the system comprising:
the data acquisition module is used for acquiring loaded data, stress data and cross beam mid-span deflection of the gantry crane;
the data calculation module is used for determining the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit according to the loaded data;
The state early warning module is used for carrying out operation state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value;
and the visualization module is used for generating a maximum combined stress cloud image according to the maximum combined stress, generating a gantry crane deformation cloud image according to the displacement value, displaying the maximum combined stress cloud image and the gantry crane deformation cloud image on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information.
In some embodiments, the system further comprises:
and the cloud database is used for storing the loaded data, the stress data, the cross beam mid-span deflection, the maximum combined stress of the beam units and the displacement value of the nodes of the beam units.
In some embodiments, the data acquisition module comprises:
the side pressure tension sensor is arranged on the lifting hook of the gantry crane and is used for monitoring the load value of the gantry crane;
the photoelectric encoder is arranged on the crown block of the gantry crane and is used for monitoring the loaded position of the gantry crane;
the surface strain gauge is respectively arranged at the middle position of the cross beam of the gantry crane and the middle part of the supporting leg and is used for monitoring the stress data;
And the static leveling instrument is respectively arranged at the leftmost end of the cross beam of the gantry crane and the midspan position of the cross beam and is used for monitoring the midspan deflection of the cross beam.
The application provides a monitoring method and a monitoring system for the running state of a gantry crane, wherein the method comprises the steps of obtaining loaded data, stress data and mid-span deflection of a cross beam of the gantry crane; determining the maximum combined stress of a beam unit of the gantry crane and the displacement value of a node of the beam unit according to the loaded data; performing running state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value; generating a maximum combined stress cloud picture according to the maximum combined stress, generating a gantry crane deformation cloud picture according to the displacement value, displaying the maximum combined stress cloud picture and the gantry crane deformation cloud picture on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information. The comprehensive monitoring of the gantry crane state is realized, the comprehensiveness and reliability of the gantry crane running state early warning are improved, and the running state of the gantry crane can be displayed more intuitively through various information visualizations.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic flow chart of a method for monitoring an operation state of a gantry crane according to an embodiment of the present application;
FIG. 2 is a schematic illustration of gantry crane sensor setup positions;
fig. 3 is a schematic block diagram of a monitoring system for an operation state of a gantry crane according to an embodiment of the present application;
FIG. 4 is a schematic illustration of the positive bending moment of the beam unit;
FIG. 5 is stored displacement data of nodes;
FIG. 6 is a stored beam unit maximum combined stress;
fig. 7 is a schematic diagram of an early warning process.
The realization, functional characteristics and advantages of the present application will be further described with reference to the embodiments, referring to the attached drawings.
Detailed Description
The following description of the embodiments of the present application will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are some, but not all, of the embodiments of the present application. All other embodiments, which can be made by one of ordinary skill in the art without undue burden from the present disclosure, are within the scope of the present disclosure.
The flow diagrams depicted in the figures are merely illustrative and not necessarily all of the elements and operations/steps are included or performed in the order described. For example, some operations/steps may be further divided, combined, or partially combined, so that the order of actual execution may be changed according to actual situations.
The embodiment of the application provides a monitoring method and a monitoring system for the running state of a gantry crane.
Some embodiments of the present application are described in detail below with reference to the accompanying drawings. The following embodiments and features of the embodiments may be combined with each other without conflict.
Referring to fig. 1, fig. 1 is a flow chart of a method for monitoring an operation state of a gantry crane according to an embodiment of the present application.
As shown in fig. 1, the method includes steps S1 to S4.
And S1, acquiring loading data, stress data and beam mid-span deflection of the gantry crane.
Specifically, the acquiring the loaded data, the stress data and the cross beam mid-span deflection of the gantry crane comprises:
monitoring a load value of the gantry crane through a side pressure tension sensor arranged on a lifting hook of the gantry crane, and monitoring a loaded position of the gantry crane through a photoelectric encoder arranged on a crown block of the gantry crane; monitoring the stress data through surface strain gauges respectively arranged at the cross beam midspan position of the gantry crane and the middle part of the supporting leg; and monitoring the beam midspan deflection through a static level gauge respectively arranged at the leftmost end of the beam of the gantry crane and the midspan position of the beam.
In this embodiment, the loading data, stress data and cross beam mid-span deflection of the gantry crane are obtained by a data acquisition module composed of a plurality of sensors arranged on the gantry crane. As shown in fig. 2, the data acquisition module includes: the side pressure tension sensor is arranged on the sling above the lifting hook and used for monitoring the lifting hook weight, and the monitored lifting hook weight is the monitored load value of the gantry crane; the 1 photoelectric encoder is arranged on the crown block and used for monitoring the position of the crown block on the cross beam, and the monitored position of the crown block on the cross beam is the loaded position of the gantry crane; the 5 surface strain gauges are arranged at the midspan part of the cross beam and the middle part of the supporting leg and are used for measuring the stress values of the sites; and 2 static leveling instruments, wherein one of the static leveling instruments is arranged at the leftmost end of the cross beam of the gantry crane and is used as a position reference, and the other static leveling instrument is arranged at the cross beam midspan position of the gantry crane and is used for measuring the cross beam midspan deflection value. As shown in fig. 3, data obtained by monitoring a sensor in the data acquisition module is transmitted to a cloud database for storage through a data acquisition device and a data transmission device in the data acquisition module through a wireless network.
It is worth noting that the pymysql sub-library of Python can be used on a computer device to connect to the cloud database and extract data measured in real time on site by the sensor. Wherein pymysql is the interface from Python to MySQL database server.
And S2, determining the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit according to the loaded data.
In some embodiments, the determining the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit according to the loaded data includes:
applying load and boundary conditions to a preset gantry crane finite element model according to the load value and the loaded position; calculating and obtaining the intra-unit force of the beam unit and the displacement value of the node of the beam unit through the gantry crane finite element model; calculating and obtaining the maximum combined stress of the beam unit according to the intra-unit force of the beam unit; wherein the in-cell forces of the beam cell include axial forces, bending moments and shear forces.
The load and boundary conditions of the gantry crane finite element model established in advance can be applied in Python by using a feon sub-library according to the weight of the lifting hook, namely the load value, stored in a cloud database and the position of the crown block on the cross beam, namely the loaded position of the gantry crane, through a data calculation module in computer equipment, and then the intra-unit forces of all beam units of the gantry crane and the displacement of all nodes are calculated according to the gantry crane finite element model with the applied load and boundary conditions, wherein the intra-unit forces of the beam units comprise axial force, bending moment and shearing force.
Further, after the intra-unit force of the beam unit of the gantry crane is obtained, the maximum combined stress of the beam unit is obtained through calculation according to the intra-unit force of the beam unit. As shown in fig. 4, since a beam unit has two nodes I, J, the magnitude of the bending moment is different in the two sections where the two nodes I, J are located, the maximum combined stress needs to be calculated in the section I, J, and then the value with the larger absolute value is taken as the final maximum combined stress value of the beam unit. The calculation formula of the maximum combined stress of the I section is given below:
wherein S is MCS Is the maximum combined stress of the I section, S ax Is the axial stress of the beam unit, S by1 、S by2 Is a bending moment M z Positive stress caused by S bz1 、S bz2 Is a bending moment M y Positive stress is induced.
S ax 、S by1 、S by2 、S bz1 And S is bz2 The expression is as follows:
where N is the beam element axial force (the beam element is pulled positive and pressed negative), and a is the beam element cross-sectional area (the beam element cross-sectional area remains unchanged along the element local coordinate axis x-axis).
M in the formula Iz Is a bending moment about the z-axis on the I section, C yp I to the distance from the central axis to the edge fibers in the beam unit cross-section in the +y-axis direction of the beam unit local coordinate system zz Is the moment of inertia of the beam unit cross section to the z-axis.
C in the formula ym The distance from the central axis to the edge fiber in the beam unit cross section is in the beam unit local coordinate system-y axis direction.
M in the formula Iy Is a bending moment about the y-axis on the I section, C zp I for the distance from the central axis to the edge fibers in the beam unit cross-section in the +z-axis direction along the beam unit local coordinate system yy Is the moment of inertia of the beam unit cross section to the y-axis.
C in the formula zm The distance from the central axis to the edge fiber in the beam unit cross section is taken along the beam unit local coordinate system-z-axis direction.
It should be noted that, the local coordinate system of the beam unit is a right-hand rectangular coordinate system, the x-axis points from the I-node (local origin of coordinates) to the J-node, and the positive direction of the bending moment is shown in fig. 4. The calculation method of the J section is similar to the calculation method of the I section, and will not be described in detail here.
As shown in fig. 5, all the calculated node displacement data are stored in a cloud database, wherein the displacement unit of the node is m. As shown in fig. 6, the calculated intra-unit forces of all beam units, including axial force, bending moment and shearing force, and the maximum combined stress of the beam units obtained by formula calculation are stored in a cloud database, and the combined stress unit is KPa.
And S3, carrying out running state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value.
Specifically, the performing the operation state early warning of the gantry crane according to the loaded data, the stress data, the beam mid-span deflection, the maximum combined stress and the displacement value includes:
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding first threshold values, a first-level early warning signal is sent to perform first-level running state early warning; when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding second threshold values, a secondary early warning signal is sent to perform secondary running state early warning; when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding third threshold values, a three-level early warning signal is sent to perform three-level operation state early warning; wherein the third threshold is greater than the second threshold, the second threshold being greater than the first threshold.
Exemplary, as shown in fig. 7, in this embodiment, the early warning of the running state of the gantry crane is implemented through a hierarchical early warning module connected to the cloud database. The early warning module can comprehensively judge and warn according to the data actually measured by the sensor and the result calculated by the data calculation module stored in the cloud database, and store warning information into the cloud database. In the embodiment, the operation state early warning of the gantry crane is divided into three levels, the first-level operation state early warning is a prompt early warning, the second-level operation state early warning is a warning early warning, the third-level operation state early warning is a warning early warning, and the specific contents of the three levels are as follows:
When any one of the load value, stress data, cross beam mid-span deflection or maximum combined stress or displacement value obtained by on-line calculation measured by the sensor exceeds a first threshold corresponding to the corresponding primary operation state early warning, the primary early warning signal sent out reminds monitoring personnel to pay attention to strengthen the observation of the structure.
When any one of the load value, stress data, cross beam mid-span deflection or maximum combined stress or displacement value obtained by on-line calculation measured by the sensor exceeds a second threshold corresponding to the corresponding second-level running state early warning, the sent second-level early warning signal reminds monitoring and related personnel to take measures to adjust the structure, and construction is continued.
When any one of the load value, stress data, cross-middle deflection of the cross beam or the maximum combined stress or displacement value obtained by on-line calculation measured by the sensor exceeds a third threshold corresponding to the corresponding three-level operation state early warning, the sent three-level early warning signal reminds that the construction should be stopped immediately, emergency treatment measures are taken to prevent accidents, and relevant personnel are immediately required to analyze reasons, and the construction can be further processed for the next construction.
In some embodiments, loading the conditions that the loaded position of the gantry crane is a beam midspan position, a rated lifting value of the gantry crane with a first preset multiple, the dead weight load of the gantry crane, a preset horizontal inertial load and a preset wind load into a preset gantry crane finite element model, and obtaining first thresholds corresponding to the stress data and the beam midspan deflection respectively; loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain second thresholds respectively corresponding to the stress data and the cross beam midspan deflection; loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load of the gantry crane into a preset gantry crane finite element model to obtain third thresholds respectively corresponding to the stress data and the cross beam midspan deflection.
In this embodiment, the rated lifting value of the gantry crane is set as Gn, and for determining the threshold corresponding to the stress data of the gantry crane and the mid-span deflection of the cross beam, the situations that the dead load is 0.95Gn, 1.10Gn and 1.25Gn are mainly considered, and each parameter is substituted into the gantry crane finite element model to calculate various working conditions to obtain each parameter threshold.
Specifically, when the first threshold value corresponding to the gantry crane stress data and the cross beam mid-span deflection is calculated, the trolley is moved to the cross beam mid-span position, and the load combination is obtained by loading dead weight load, dead load corresponding to the threshold value 0.95Gn (considering impact coefficient), horizontal inertial load and wind load as conditions into a gantry crane finite element model.
When the second threshold value corresponding to the gantry crane stress data and the cross beam mid-span deflection is calculated, the trolley is moved to the cross beam mid-span position, and the load combination is calculated by taking dead weight load, dead load 1.10Gn (considering impact coefficient) corresponding to the threshold value, horizontal inertial load and wind load as conditions and loading the conditions into the gantry crane finite element model.
When the third threshold value corresponding to the gantry crane stress data and the cross beam mid-span deflection is calculated, the trolley is moved to the cross beam mid-span position, and the load combination is calculated by taking dead weight load, dead load 1.25Gn (considering impact coefficient) corresponding to the threshold value, horizontal inertial load and wind load as conditions and loading the conditions into the gantry crane finite element model.
Further, after the first threshold value, the second threshold value and the third threshold value of the beam mid-span deflection corresponding to the beam mid-span deflection are obtained through calculation, the method further comprises the steps of: determining whether the obtained beam mid-span deflection third threshold corresponding to the beam mid-span deflection is larger than a preset beam mid-span deflection limit threshold. If so, taking a cross beam mid-span deflection limit threshold value with a fourth preset multiple as a cross beam mid-span deflection first threshold value, taking a cross beam mid-span deflection limit threshold value with a fifth preset multiple as a cross beam mid-span deflection second threshold value, and taking the cross beam mid-span deflection limit threshold value as a cross beam mid-span deflection third threshold value, wherein the fifth preset multiple is larger than the fourth preset threshold value.
It is worth to say that, in addition, to the calculation of the limit threshold value of the cross deflection of the gantry crane cross beam, the static rigidity requirement of the crane is also considered, and the value of the cross deflection limit threshold value of the cross beam corresponding to the cross deflection of the cross beam is as follows:
f is a cross beam mid-span deflection limit threshold, S is a gantry crane span, and C is a constant parameter, which takes a value according to the positioning accuracy of the gantry crane. Gantry crane with low positioning precision requirement or gantry crane with stepless speed regulation control characteristic, and gantry crane C with low lifting speed and low acceleration to reach acceptable positioning precision 500; the gantry crane C is 750, which can achieve the characteristic of medium positioning precision by using a simple control system; the gantry crane C, which requires high positioning accuracy characteristics, takes 1000. The alarm threshold, i.e. the third threshold, of the mid-span deflection of the gantry crane should not exceed this value.
When the third threshold value of the cross beam mid-span deflection is larger than the limit threshold value of the cross beam mid-span deflection, the first threshold value of the cross beam mid-span deflection is 0.8f, the second threshold value of the cross beam mid-span deflection is 0.9f, and the third threshold value of the cross beam mid-span deflection is f.
As a preferable real-time mode, when the primary warning signal, the secondary warning signal or the tripolar warning signal is turned off, if the operation state warning level is increased, a warning signal of a corresponding level is sent out, if the operation state warning level is the same or is decreased, no warning signal is sent out any more, and information of operation state warning is stored.
After the early warning threshold is determined, once the measured parameter or the online calculation result of the sensor exceeds a threshold of a certain level, alarming prompt is carried out through Python programming, and abnormal data is stored into a cloud database through a pymysql sub-database. Finally, python programming is needed to realize the following alarm functions: when the alarm prompt is closed, the alarm prompt with the same level is not displayed for a period of time, only the alarm information is stored continuously, if the alarm level is lifted, the prompt with the current alarm level is displayed immediately, if the alarm prompt is closed, the alarm prompt with the same level or lower level is not displayed for the same period of time, and the like.
And S4, generating a maximum combined stress cloud picture according to the maximum combined stress, generating a gantry crane deformation cloud picture according to the displacement value, displaying the maximum combined stress cloud picture and the gantry crane deformation cloud picture on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information.
The maximum combined stress cloud image, the gantry crane deformation cloud image generated according to the displacement value and the loaded data are generated and displayed through a visualization module. Specifically, using Python programming to directly derive an obj file of a gantry crane model, combining a maximum combined stress and displacement value stored in a cloud database, displaying a stress cloud image or a gantry crane deformation cloud image of the gantry crane three-dimensional model in a webpage through analysis processing of back-end data, and placing color bars beside the cloud image to display corresponding color values; secondly, displaying the loading condition of the gantry crane in a webpage according to the position of the crown block and the crane weight data in the database; and finally, displaying the alarm part and the alarm information in the webpage in real time according to the alarm information in the database.
It should be noted that, in this embodiment, the maximum combined stress cloud image is divided into 13 levels according to RGB colors, and the closer the stress portion is to the blue, the more severe the stress is represented by the closer to the red, the more severe the stress is represented by the closer to the green, and the less the stress is represented by the closer to the green. For the deformation cloud image of the gantry crane, the closer a certain part of the gantry crane is to blue, the larger the negative displacement of the node of the part is, the closer the red is, the larger the positive displacement of the node of the part is, the closer the green is, the smaller the displacement is, and the positive and negative of the displacement are judged according to the positive direction of the global coordinate axis.
As a preferred implementation mode, when the operation state early warning of a certain part of the gantry crane is displayed, the visualization module displays a specific part where the early warning occurs and specific early warning information by using a green mark when the operation state early warning of the certain part of the gantry crane is a primary operation state early warning. When the operation state early warning of a certain part is the secondary operation state early warning, the specific part where the early warning occurs and specific early warning information are displayed by using an orange mark. When the operation state early warning of a certain part is three-level operation state early warning, a red mark is used for displaying the specific part where the early warning occurs and specific early warning information.
In this embodiment, the calculation of the maximum combined stress of the beam units of the gantry crane and the displacement values of the nodes of the beam units is performed periodically. The data calculation module judges whether an instruction for stopping calculation is input, if the instruction is received, the calculation is finished, the circulation is stopped, if the instruction is not received, the load value of the gantry crane and the loaded position of the gantry crane are updated once in 2 seconds according to the actual measurement data of the sensor, the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit are calculated according to the load value and the loaded position, and the maximum combined stress cloud picture and the gantry crane deformation cloud picture are updated.
The embodiment provides a method for monitoring the running state of a gantry crane, which comprises the steps that firstly, actual loaded data, stress data and cross beam mid-span deflection of the gantry crane can be comprehensively obtained through a sensor, deformation and stress values of all positions on the gantry crane can be calculated according to the loaded data, and the method is not limited to measuring points, so that stress safety of the gantry crane structure can be pre-warned no matter whether the measuring points are stresses of non-measuring points or the deformation exceeds a threshold value, the problem that the pre-warning stress measuring points are insufficient and incomplete is solved, and the sensor measured values at the measuring point positions can be comprehensively combined to perform pre-warning judgment, so that the possibility of false alarm and missing alarm due to measuring deviation of the sensor can be reduced, and the pre-warning reliability is improved; secondly, the real-time online data calculation module solves the current situation of severe fracture in the traditional health monitoring technology and mechanical calculation; finally, the invention can more intuitively display the current working state and stress deformation state of the gantry crane through the state early warning module and the real-time online visualization module, and once an alarm appears, the position of the risk stress structure is clear at a glance.
In a second aspect, an embodiment of the present application further provides a monitoring system for an operating state of a gantry crane, as shown in fig. 3, where the system includes:
The data acquisition module is used for acquiring loaded data, stress data and cross beam mid-span deflection of the gantry crane;
the data calculation module is used for determining the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit according to the loaded data;
the state early warning module is used for carrying out operation state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value;
and the visualization module is used for generating a maximum combined stress cloud image according to the maximum combined stress, generating a gantry crane deformation cloud image according to the displacement value, displaying the maximum combined stress cloud image and the gantry crane deformation cloud image on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information.
Wherein the system further comprises:
and the cloud database is used for storing the loaded data, the stress data, the cross beam mid-span deflection, the maximum combined stress of the beam units and the displacement value of the nodes of the beam units.
Wherein, the data acquisition module still includes:
the side pressure tension sensor is arranged on the lifting hook of the gantry crane and is used for monitoring the load value of the gantry crane;
The photoelectric encoder is arranged on the crown block of the gantry crane and is used for monitoring the loaded position of the gantry crane;
the surface strain gauge is respectively arranged at the middle position of the cross beam of the gantry crane and the middle part of the supporting leg and is used for monitoring the stress data;
and the static leveling instrument is respectively arranged at the leftmost end of the cross beam of the gantry crane and the midspan position of the cross beam and is used for monitoring the midspan deflection of the cross beam.
Wherein the data calculation module is further configured to:
applying load and boundary conditions to a preset gantry crane finite element model according to the load value and the loaded position;
calculating and obtaining the intra-unit force of the beam unit and the displacement value of the node of the beam unit through the gantry crane finite element model;
calculating and obtaining the maximum combined stress of the beam unit according to the intra-unit force of the beam unit;
wherein the in-cell forces of the beam cell include axial forces, bending moments and shear forces.
Wherein, the state early warning module is further used for:
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding first threshold values, a first-level early warning signal is sent to perform first-level running state early warning;
When the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding second threshold values, a secondary early warning signal is sent to perform secondary running state early warning;
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding third threshold values, a three-level early warning signal is sent to perform three-level operation state early warning;
wherein the third threshold is greater than the second threshold, the second threshold being greater than the first threshold.
Wherein, the state early warning module is further used for:
when the primary early warning signal, the secondary early warning signal or the tripolar early warning signal is closed, if the operation state early warning level is increased, an early warning signal of a corresponding level is sent out, and if the operation state early warning level is the same or is reduced, the early warning signal is not sent out any more, and information of operation state early warning is stored.
Wherein, the state early warning module is further used for:
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain first thresholds respectively corresponding to the stress data and the cross beam midspan deflection;
Loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain second thresholds respectively corresponding to the stress data and the cross beam midspan deflection;
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load of the gantry crane into a preset gantry crane finite element model to obtain third thresholds respectively corresponding to the stress data and the cross beam midspan deflection.
Wherein, the state early warning module is further used for:
determining whether a third threshold value of the beam mid-span deflection corresponding to the obtained beam mid-span deflection is larger than a preset beam mid-span deflection limit threshold value;
if yes, taking a cross beam mid-span deflection limit threshold value of a fourth preset multiple as a cross beam mid-span deflection first threshold value, taking a cross beam mid-span deflection limit threshold value of a fifth preset multiple as a cross beam mid-span deflection second threshold value, and taking the cross beam mid-span deflection limit threshold value as a cross beam mid-span deflection third threshold value, wherein the fifth preset multiple is larger than the fourth preset multiple;
Wherein, the value of the cross beam mid-span deflection limit threshold is as follows:
f is the cross beam mid-span deflection limit threshold, S is the span of the gantry crane, and C is a constant parameter, wherein the constant parameter is valued according to the positioning accuracy of the gantry crane.
It should be noted that, for convenience and brevity of description, specific working procedures of the above-described apparatus and each module and unit may refer to corresponding procedures in the foregoing embodiments, and are not repeated herein.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or system. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or system that comprises the element.
The foregoing embodiment numbers of the present application are merely for describing, and do not represent advantages or disadvantages of the embodiments. While the invention has been described with reference to certain preferred embodiments, it will be understood by those skilled in the art that various changes and substitutions of equivalents may be made and equivalents will be apparent to those skilled in the art without departing from the scope of the invention. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
Claims (10)
1. The method for monitoring the running state of the gantry crane is characterized by comprising the following steps of:
acquiring loading data, stress data and cross beam mid-span deflection of the gantry crane;
determining the maximum combined stress of a beam unit of the gantry crane and the displacement value of a node of the beam unit according to the loaded data;
performing running state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value;
generating a maximum combined stress cloud picture according to the maximum combined stress, generating a gantry crane deformation cloud picture according to the displacement value, displaying the maximum combined stress cloud picture and the gantry crane deformation cloud picture on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information.
2. The method for monitoring the running state of the gantry crane according to claim 1, wherein the steps of obtaining the loading data, the stress data and the beam mid-span deflection of the gantry crane comprise:
monitoring a load value of the gantry crane through a side pressure tension sensor arranged on a lifting hook of the gantry crane, and monitoring a loaded position of the gantry crane through a photoelectric encoder arranged on a crown block of the gantry crane;
Monitoring the stress data through surface strain gauges respectively arranged at the cross beam midspan position of the gantry crane and the middle part of the supporting leg;
and monitoring the beam midspan deflection through a static level gauge respectively arranged at the leftmost end of the beam of the gantry crane and the midspan position of the beam.
3. The method of monitoring the operational state of a gantry crane according to claim 2, wherein said determining the maximum combined stress of the beam units of the gantry crane and the displacement value of the nodes of the beam units based on the loaded data comprises:
applying load and boundary conditions to a preset gantry crane finite element model according to the load value and the loaded position;
calculating and obtaining the intra-unit force of the beam unit and the displacement value of the node of the beam unit through the gantry crane finite element model;
calculating and obtaining the maximum combined stress of the beam unit according to the intra-unit force of the beam unit;
wherein the in-cell forces of the beam cell include axial forces, bending moments and shear forces.
4. The method for monitoring the running state of the gantry crane according to claim 2, wherein the step of performing the running state early warning of the gantry crane according to the load data, the stress data, the beam mid-span deflection, the maximum combined stress and the displacement value comprises the steps of:
When the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding first threshold values, a first-level early warning signal is sent to perform first-level running state early warning;
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding second threshold values, a secondary early warning signal is sent to perform secondary running state early warning;
when the load value, the stress data and the cross beam mid-span deflection of the gantry crane are higher than the corresponding third threshold values, a three-level early warning signal is sent to perform three-level operation state early warning;
wherein the third threshold is greater than the second threshold, the second threshold being greater than the first threshold.
5. The method of monitoring the operational status of a gantry crane of claim 4, further comprising:
when the primary early warning signal, the secondary early warning signal or the tripolar early warning signal is closed, if the operation state early warning level is increased, an early warning signal of a corresponding level is sent out, and if the operation state early warning level is the same or is reduced, the early warning signal is not sent out any more, and information of operation state early warning is stored.
6. The method of monitoring the operational status of a gantry crane of claim 4, further comprising:
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain first thresholds respectively corresponding to the stress data and the cross beam midspan deflection;
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load into a preset gantry crane finite element model to obtain second thresholds respectively corresponding to the stress data and the cross beam midspan deflection;
loading the conditions that the loaded position of the gantry crane is the cross beam midspan position, the rated lifting value of the gantry crane, the dead weight load of the gantry crane, the preset horizontal inertial load and the preset wind load of the gantry crane into a preset gantry crane finite element model to obtain third thresholds respectively corresponding to the stress data and the cross beam midspan deflection.
7. The method of monitoring the operational status of a gantry crane of claim 6, further comprising:
determining whether a third threshold value of the beam mid-span deflection corresponding to the obtained beam mid-span deflection is larger than a preset beam mid-span deflection limit threshold value;
if yes, taking a cross beam mid-span deflection limit threshold value of a fourth preset multiple as a cross beam mid-span deflection first threshold value, taking a cross beam mid-span deflection limit threshold value of a fifth preset multiple as a cross beam mid-span deflection second threshold value, and taking the cross beam mid-span deflection limit threshold value as a cross beam mid-span deflection third threshold value, wherein the fifth preset multiple is larger than the fourth preset multiple;
wherein, the value of the cross beam mid-span deflection limit threshold is as follows:
f is the cross beam mid-span deflection limit threshold, S is the span of the gantry crane, and C is a constant parameter, wherein the constant parameter is valued according to the positioning accuracy of the gantry crane.
8. A monitoring system for the operational status of a gantry crane, comprising:
the data acquisition module is used for acquiring loaded data, stress data and cross beam mid-span deflection of the gantry crane;
the data calculation module is used for determining the maximum combined stress of the beam unit of the gantry crane and the displacement value of the node of the beam unit according to the loaded data;
The state early warning module is used for carrying out operation state early warning on the gantry crane according to the loaded data, the stress data and the cross beam mid-span deflection, the maximum combined stress and the displacement value;
and the visualization module is used for generating a maximum combined stress cloud image according to the maximum combined stress, generating a gantry crane deformation cloud image according to the displacement value, displaying the maximum combined stress cloud image and the gantry crane deformation cloud image on a three-dimensional model of the gantry crane, and displaying the loaded data and the running state early warning information.
9. The method of monitoring the operational status of a gantry crane of claim 8, wherein the system further comprises:
and the cloud database is used for storing the loaded data, the stress data, the cross beam mid-span deflection, the maximum combined stress of the beam units and the displacement value of the nodes of the beam units.
10. The gantry crane operating condition monitoring system of claim 8, wherein the data acquisition module comprises:
the side pressure tension sensor is arranged on the lifting hook of the gantry crane and is used for monitoring the load value of the gantry crane;
the photoelectric encoder is arranged on the crown block of the gantry crane and is used for monitoring the loaded position of the gantry crane;
The surface strain gauge is respectively arranged at the middle position of the cross beam of the gantry crane and the middle part of the supporting leg and is used for monitoring the stress data;
and the static leveling instrument is respectively arranged at the leftmost end of the cross beam of the gantry crane and the midspan position of the cross beam and is used for monitoring the midspan deflection of the cross beam.
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| CN117828954A (en) * | 2024-03-04 | 2024-04-05 | 质子汽车科技有限公司 | Swing arm fatigue analysis method and system considering contact state and electronic equipment |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117828954A (en) * | 2024-03-04 | 2024-04-05 | 质子汽车科技有限公司 | Swing arm fatigue analysis method and system considering contact state and electronic equipment |
| CN117828954B (en) * | 2024-03-04 | 2024-06-07 | 质子汽车科技有限公司 | Swing arm fatigue analysis method and system considering contact state and electronic equipment |
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