CN101042372B - Detection processing system for mobile defect of steel beam structure - Google Patents

Abstract

This invention discloses one test process system and method for harbor large crane steel beam structure action deficiency, wherein, the process system comprises test part, signal analysis part and signal processor; the test part outputs analogue information processor to convert digital electrical information f3 to signal analysis part; signal analysis part adopts limit even comparison method for testing to get active deficiency in steel structure position information f4; then downloading the position information f4 to spot use; the test part comprises sensor, front amplifier by cable. This signal analysis part comprises computer, deficiency active position analysis module into computer memory.

Description

The detecting processing system of mobile defect of steel beam structure

Technical field

The present invention relates to a kind of defects detection disposal system, more particularly say, be meant that defective that a kind of steel beam structure that is applicable to the harbour goliath exists in use for some time detects the system of processing, thereby provide safer, more reliable running environment for the harbour goliath in using.

Background technology

Harbour large lifting equipment such as harbor portal crane, bulk goods ship unloaders, shore container crane, power plant's coal ship unloaders etc. in the status and the effect of port and pier, are always paid close attention to by people and are paid attention to.As the important techniques material base, it has embodied the level of the productive forces at a harbour.Have as the harbour main equipment that investment is big, benefit is big,, also can cause certain international influence if it is bigger its economic loss of accident to occur.

How large-scale in detection and the analysis and assessment of carrying out security with plant equipment to the harbour, its life-span of scientific and reasonable prolongation, being not only the problem that harbour management person and technical staff author very pay close attention to, also is one of research focus of at present domestic and international academia and engineering circle.

The life-span of harbour goliath complete machine is often depended on the life-span of key structure spare.By to the crash analysis of steel beam structure in the crane with discover that mobile defect reasons such as (tired running cracks) is to cause the main cause of structural failure.The germinating of fatigue crack and spreading fracture usually have following feature: 1) heredity; 2) parasitics; 3) difficult detection property; 4) comprehensive; 5) sudden, generally there is not omen.Therefore effective and safe detection and the safety assessment difficulty to these harbour large lifting equipments just seems extremely important.

Usually adopt conventional Dynamic Non-Destruction Measurement that the harbour goliath is carried out safety detection (as UT (Ultrasonic Testing), magnetic powder inspection, rays method etc.) at present, adopt mechanical analysis or simple analysis of fatigue to carry out safety assessment.These safety detection and safety evaluation method are that certain contribution has been made in the safety management of harbour machinery equipment, but the omission phenomenon appears in above-mentioned technology easily, can't fast and effeciently judge defective locations, has a strong impact on the safe operation of equipment.

Summary of the invention

The purpose of this invention is to provide a kind of detecting processing system that is applicable to the mobile defect of steel beam structure of harbour goliath, this mobile defect detecting processing system adopts acoustic emission that mobile defect information is gathered, then described Information Monitoring is used the arithmetic capability of computing machine, and the digitizing, the intelligent mode that combine with defective moving position analysis module are carried out the mobile defect location positioning.

Another object of the present invention is to propose a kind of detection disposal route that is applicable to the mobile defect of steel beam structure of harbour goliath, this mobile defect detects disposal route and obtains the mobile defect incident by the incident limit analysis, perhaps obtain the mobile defect incident by the amplitude equalizing value after amplitude limits is analyzed, then the mobile defect incident is effectively discerned, thereby solved problems such as the scope of activities that can't effectively judge defective for a long time and omission phenomenon.

The present invention is a kind of detecting processing system that is applicable to the mobile defect of steel beam structure of harbour goliath, and this mobile defect detecting processing system comprises test section, signal analysis part and signal processor, the analog information f of described test section output ₂Output digital telecommunication breath f after described signal processor conversion ₃Give described signal analysis part, the digital telecommunication breath f of described signal analysis part to receiving ₃Adopt the average pairing comparision of the limit to carry out mobile defect and judge, obtain the positional information f of mobile defect on steel construction ₄, then with described positional information f ₄Export or be downloaded to on-the-spot the use by the delivery outlet (USB interface, serial communication interface) of computing machine; Described test section includes sensor, prime amplifier, and sensor and prime amplifier adopt wired connection; Described signal analysis part includes computing machine, defective moving position analysis module, and defective moving position analysis module is stored in the storer of computing machine.

The advantage of mobile defect detecting processing system of the present invention is: (1) makes the mobile defect of steel beam structure detect more effective by introducing computing machine and software mathematical model; (2) defective moving position analysis module adopts the limit average modeling of mathematical theory, and making efficiently, detection means applies in the defects detection of harbour goliath; (3) defective moving position analysis module adopts the judging means of many conditions, has improved recall rate and accuracy rate; (4) the conventional Dynamic Non-Destruction Measurement of defects detection efficiency ratio (UT (Ultrasonic Testing)) has improved 40～65%, and recall rate is up to 90～98%, for the safe operation of equipment provides guarantee.

The advantage that mobile defect of the present invention detects disposal route is: (1) is to picking up digital telecommunication breath f ₃Adopted and once picked up repeatedly utilization, improved work efficiency effectively, simultaneously the data source that provides mobile defect to detect for incident limit analysis, amplitude limits analysis; (2) to incident E _i, amplitude X _iAnalysis succinctly effective; (3) detect equipment needed thereby, device is less relatively, reduced mobile defect effectively and detected cost.

Description of drawings

Fig. 1 is the steel construction defects detection structural representation block diagram of harbour goliath.

Fig. 2 is a defects detection modular structure schematic block diagram of the present invention.

Embodiment

The present invention is described in further detail below in conjunction with drawings and Examples.

See also shown in Figure 1, the present invention is a kind of detecting processing system that is applicable to the mobile defect of steel beam structure of harbour goliath, this mobile defect detecting processing system comprises test section, signal analysis part and signal processor, the analog information f of described test section output ₂Output digital telecommunication breath f after described signal processor conversion ₃Give described signal analysis part, the digital telecommunication breath f of described signal analysis part to receiving ₃Adopt the average pairing comparision of the limit to carry out mobile defect and judge, obtain the positional information f of mobile defect on steel construction ₄, then with described positional information f ₄Export or be downloaded to on-the-spot the use by the delivery outlet (USB interface, serial communication interface) of computing machine; Described test section includes sensor, prime amplifier, and sensor and prime amplifier adopt wired connection; Described signal analysis part includes computing machine, defective moving position analysis module, and defective moving position analysis module is stored in the storer of computing machine;

Described sensor is with the mobile defect information f of gathering ₁Export to described prime amplifier;

The described mobile defect information f of described prime amplifier to receiving ₁Output analog information f after processing and amplifying ₂Give described signal processor;

The described analog information f of described signal processor to receiving ₂Output digital telecommunication breath f after conversion process ₃Give the described defective moving position analysis module that is stored in the computing machine;

The digital telecommunication breath f of described defective moving position analysis module to receiving ₃After carrying out defective moving position analyzing and processing, obtain the positional information f of mobile defect on steel construction ₄, then by the output of computing machine delivery outlet.

In the present invention, the digital telecommunication breath f of described defective moving position analysis module to receiving ₃The treatment step that carries out is:

The first step: pick up digital telecommunication breath f ₃

Described digital telecommunication breath f ₃In include incident E _i(i=1 wherein, 2,3 ... N, N are positive integer), measure Ring-down count n, rise time t, duration T, measuring amplitude X _i(i=1 wherein, 2,3 ... N, N are positive integer);

Second step: the incident limit analysis is handled

Incident Ei is satisfied the incident limit relation handle acquisition mobile defect incident E _i(V),

Described incident limit relation is $E_i\left(V\right)=\left\{\begin{array}{cc}{E}_i& (t>10{\mathrm{\&mu;}}_s)\&cap;(T>110{\mathrm{\&mu;}}_s)\\ 0& (t<10{\mathrm{\&mu;}}_s)\&cup;(T<110{\mathrm{\&mu;}}_s)\end{array}\right.,$

In the formula, E _iThe presentation of events number, E _i(V) expression mobile defect incident number, wherein V represents the validity event number, and t represents the rise time, and T represents the duration.

The 3rd step: amplitude limits analyzing and processing

To measuring amplitude X _iSatisfy the amplitude limits relation and handle acquisition mobile defect amplitude X _i(V);

Described amplitude limits is closed $X_i\left(V\right)=\left\{\begin{array}{cc}{X}_i& (t>10{\mathrm{\&mu;}}_s)\&cap;(T>110{\mathrm{\&mu;}}_s)\&cap;(n>3)\\ 0& (t<10{\mathrm{\&mu;}}_s)\&cup;(T<110{\mathrm{\&mu;}}_s)\end{array}\right.,$

In the formula, X _iThe expression measuring amplitude, X _i(V) expression mobile defect amplitude, wherein V represents the validity event number, and t represents the rise time, and T represents the duration, and n represents to measure Ring-down count.

The 4th step: mobile defect amplitude equalizing value analyzing and processing

Mobile defect amplitude X to the 3rd step _i(V) carry out average and handle the effective mobile defect amplitude after the process amplitude limits analyzing and processing in a certain passage that obtains

Average Described average

Be used for further decision event E _iWhether be validity event

Mobile defect amplitude X _i(V) average is ${\mathrm{\&mu;}}_{X_i}=(1/m)\underset{i=1}{\overset{m}{\mathrm{\&Sigma;}}}{X}_i\left(V\right),$ And ${\mathrm{\&mu;}}_{X_i}\&Element;[a,b]$

In the formula,

Represent in a certain passage through the effective mobile defect amplitude X after the amplitude limits analyzing and processing _i(V) average, m represents the effective mobile defect number after the process amplitude limits analyzing and processing in a certain passage, and a represents the upper limit threshold of mobile defect amplitude equalizing value, and b represents the lower threshold of mobile defect amplitude equalizing value.

The present invention can realize effective identification of mobile defect by the mobile defect check and analysis of above-mentioned treatment step; Then, the mobile defect parameter that obtains by effective identification can realize the whole fast detecting of the mobile defect of large-scale steel beam structure has been improved detection efficiency and recall rate.

Embodiment 1:

Harbour goliath girder steel, be about 15 meters, 6 of placement sensor (150KHz resonant frequency, preamplification gain are the sonic transducer of 40dB), (choose model is 2-4-6 to 6 prime amplifiers, itself and the supporting use of R15 sonic transducer), its numbering and the information of picking up are as shown in table 1, the upper threshold a=40dB of girder steel mobile defect amplitude equalizing value wherein, the threshold value lower limit b=60dB of girder steel mobile defect amplitude equalizing value.

Table 1 multiple sensor signals picks up and analyzing and processing

Interpretation of result: by in the table last analysis result as can be seen, No. 3, No. 5, No. 6 sensor does not detect validity event, does not detect mobile defect near these three sensor positions promptly can be described; No. 1, No. 2, No. 4 sensor has arrived validity event; The validity event of No. 2 sensor is very many, and No. 1, and No. 2 sensor is adjacent, can judge and No. 2 sensors between, especially have mobile defect near near the places No. 2 sensors, count E by validity event _i(V) its active situation is more serious than No. 1 and No. 4 measured mobile defects.Because No. 4, No. 5, No. 6 sensor is adjacent, and No. 5, and No. 6 sensors all do not detect validity event, can judge that No. 4 sensors of mobile defect distance that No. 4 sensor arrive are nearer, but defective is very not serious.

In order to be without loss of generality, the inventor adopts conventional Non-Destructive Testing mode of UT (Ultrasonic Testing) and mode of the present invention respectively 30 meters long girder steels to be carried out mobile defect and detects processing, and the result is as shown in table 2 in its coherent detection:

Table 2 adopts mode of the present invention and UT (Ultrasonic Testing) mode to detect comparative illustration

?	Mode of the present invention	The conventional Non-Destructive Testing mode of UT (Ultrasonic Testing)
			Measured piece	30 meters girder steels	30 meters girder steels
Detection time (minute)	30	150
			Mobile defect number (individual)	9	9
Detect number (individual)	8	6
			Accurate number (individual)	8	4
Recall rate (%)	8/9	6/9
			Accuracy rate (%)	8/8	4/6

By the girder steel of equal length is carried out the test of effective mobile defect, system of the present invention has improved about 60% than the validity event that the conventional Non-Destructive Testing of UT (Ultrasonic Testing) obtains, and recall rate has improved more than 1.5 times, more than the rate of accuracy reached to 95%.When more girder steels being carried out the mobile defect detection, system of the present invention seems even more important.Therefore, system of the present invention is by the original bulk of digitizing, intelligentized mobile defect position module, the arithmetic capability that duty is set, many condition hypothesis have realized using computing machine, reach better accurate measurement parameter, detect better safe operation environment is provided for the steel beam structure of harbour goliath carries out mobile defect.

In the present invention, (150KHz resonant frequency, preamplification gain are 40～50dB) sonic transducers to sensor employing R15 type.Signal processor adopts the full digital 40 passage DISP acoustic emission instruments of U.S. PAC company.The computing machine minimalist configuration adopts IPC-610P/P4, internal memory 512M, hard disk 20G; Defective moving position analysis module adopts Matlab and/or VC to edit.

In the present invention, the acoustic emission detection threshold 40dB of described signal processor, frequency bandwidth 100～400KHz.

The layout of sensor of the present invention can be single linear arrangement or bilinearity symmetric arrangement.It is D=T/m that sensor placement satisfies the pass, and D represents girder steel length, and unit is a rice; T represents to be arranged in the sensor number on the girder steel, and unit is individual; M represents the gap length between the sensor, and unit is a rice.General gap length m arranges 1～4 between 1.5～5 meters.The position of each sensor on girder steel adopts numbering to be provided with, numbering by correspondence is determined the position of sensor on girder steel, number to determine the passage of sensor by sensing station, each sensor is a passage, computing machine instructs output at each sensor, each sensor back information adopts repeatedly the data comparison, to guarantee the accuracy of data, wants recall rate for detection system and does early-stage preparations.

The detecting processing system of mobile defect of steel beam structure of the present invention is by the pilot work to a series of correlation analyses and research, find that a cover is comprehensive, science, complete the major port crane safety detected and the thinking and the method for safety assessment, reduce the generation of extra heavy major break down, also for safety, the reliability service of harbour heavy mechanical equipment from now on rationally lengthen the life and establish the theory and technology basis as far as possible.

Claims (5)

1. a detecting processing system that is applicable to the mobile defect of steel beam structure of harbour goliath includes test section, signal analysis part and signal processor, it is characterized in that: the analog information f of described test section output ₂Output digital telecommunication breath f after described signal processor conversion ₃Give described signal analysis part, the digital telecommunication breath f of described signal analysis part to receiving ₃Adopt the average pairing comparision of the limit to carry out mobile defect and judge, obtain the positional information f of mobile defect on steel construction ₄

Described test section includes sensor, prime amplifier, and sensor and prime amplifier adopt wired connection;

Described signal analysis part includes computing machine, defective moving position analysis module, and defective moving position analysis module is stored in the storer of computing machine.

2. the detecting processing system of mobile defect of steel beam structure according to claim 1 is characterized in that: it is the sonic transducer of 40～50dB that described sensor adopts 150KHz resonant frequency and preamplification gain.

3. the detecting processing system of mobile defect of steel beam structure according to claim 1, it is characterized in that: the layout of described sensor is single linear arrangement or bilinearity symmetric arrangement; Sensor placement satisfies D=T/m, and D represents girder steel length, and unit is a rice; T represents to be arranged in the sensor number on the girder steel, and unit is individual; M represents the gap length between the sensor, and unit is a rice.

4. the detecting processing system of mobile defect of steel beam structure according to claim 1 is characterized in that: the acoustic emission detection threshold 40dB of described signal processor, frequency bandwidth 100～400KHz.

5. the detecting processing system of mobile defect of steel beam structure according to claim 1 is characterized in that: the digital telecommunication breath f of described defective moving position analysis module to receiving ₃The treatment step that carries out is:

The first step: pick up digital telecommunication breath f ₃

Described digital telecommunication breath f ₃In include incident E _i, i=1 wherein, 2,3 ... N, N are positive integer, measurement Ring-down count n, rise time t, duration T, measuring amplitude X _i, i=1 wherein, 2,3 ... N, N are positive integer;

Second step: the incident limit analysis is handled

To incident E _iSatisfy the incident limit relation and handle acquisition mobile defect incident E _i(V),

Described incident limit relation is

In the formula, E _iThe presentation of events number, E _i(V) expression mobile defect incident number, wherein V represents the validity event number, and t represents the rise time, and T represents the duration;

The 3rd step: amplitude limits analyzing and processing

To measuring amplitude X _iSatisfy the amplitude limits relation and handle acquisition mobile defect amplitude X _i(V);

Described amplitude limits is closed

In the formula, X _iThe expression measuring amplitude, X _i(V) expression mobile defect amplitude, wherein V represents the validity event number, and t represents the rise time, and T represents the duration, and n represents to measure Ring-down count;

The 4th step: mobile defect amplitude equalizing value analyzing and processing

Mobile defect amplitude X to the 3rd step _i(V) carrying out average handles in a certain passage of acquisition through the effective mobile defect amplitude X after the amplitude limits analyzing and processing _i(V) average

Described average

Be used for further decision event E _iWhether be validity event

Mobile defect amplitude X _i(V) average is

And

In the formula,

Represent in a certain passage through the effective mobile defect amplitude X after the amplitude limits analyzing and processing _i(V) average, m represents the effective mobile defect number after the process amplitude limits analyzing and processing in a certain passage, and a represents the upper limit threshold of mobile defect amplitude equalizing value, and b represents the lower threshold of mobile defect amplitude equalizing value.

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