CN114348881B - Method for automatically reading balance point of four-bar linkage mechanism of gantry crane - Google Patents
Method for automatically reading balance point of four-bar linkage mechanism of gantry crane Download PDFInfo
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Abstract
The invention discloses a method for automatically reading balance points of a four-bar linkage mechanism of a gantry crane, which is characterized by comprising the following steps of: an absolute value encoder is arranged on a transmission shaft of a luffing mechanism of the gantry crane to obtain a real-time measurement result of the amplitude value of the luffing mechanism; and displaying the waveform corresponding to the output torque of the variable-amplitude motor through a waveform display unit, if the waveform of the output torque of the variable-amplitude motor changes between a positive value and a negative value and a time point when the output torque is 0 appears, judging that the variable-amplitude process passes through a balance point, otherwise, judging that the variable-amplitude process does not pass through the balance point. The method can provide more effective and scientific basis for the reverse detection of whether the selection of the hinge point of the four-bar structure is accurate and the reverse verification of whether the weight of the balance weight is reasonable by general technicians, has low implementation cost, can be realized by automatic control, has high intelligent degree and strong practicability, and greatly improves the safety of the operation of crane equipment and the convenience of inspection work.
Description
Technical Field
The invention relates to the technical field of handling equipment, in particular to a method for automatically reading balance points of a four-bar linkage mechanism of a gantry crane.
Background
Portal cranes are widely used for the loading and unloading of bulk cargo terminals, for example: coal, minerals, grains, sand, and the like. Among them, the four-link gantry crane is the most common port equipment in bulk cargo handling operations and is widely used.
A complete set of four-link structure and counterweight drawing of a gantry crane is designed by professional engineers according to scientific evidences such as design specifications, national execution standards, theoretical calculation, structural mechanics, stress analysis and the like after technical requirements such as amplitude parameters (11 to 38 meters), lifting load parameters (40 t), speed parameters (60 m/min) and the like of an amplitude-varying mechanism are generally met according to technical requirements in specifications, and in the calculation of the four-link structure hinge and counterweight structure, some dereferencing coefficients are different according to different conditions, so that the condition that the calculation result is different is caused, and in the process of manufacturing an object according to the drawing of a designer, factors such as a structural member welding process, a manufacturing process, an installer level, professional technical capabilities, steel material characteristics, errors of the four-link structure hinge, length errors of counterweight, the size of counterweight weight and the like, the stability of the whole mechanism is influenced finally. The standard four-bar linkage structure has the characteristics that a balance point exists in the whole amplitude variation process, the stress structure is balanced at the position of the balance point, the whole system is stable, the energy consumption of the mechanism amplitude variation motor with the balance point is minimum, and the requirement on the power of the amplitude variation motor is minimum. The counterweight is mainly used for balancing load, so that the door seat machine is stable in structure, the gravity center is near the rotation center, and the overturning problem is avoided.
If the hinge point of the four-bar structure is not properly selected, the energy consumption and power of the variable amplitude motor can be increased, and the energy consumption electric energy of the variable amplitude motor can be increased and the service life of the variable amplitude motor, a variable amplitude motor frequency converter, a variable amplitude reduction box and a variable amplitude rack can be shortened when the four-bar structure is operated in the state for a long time. And if the hinge point of the four-bar structure is not properly selected, the balance point is lost in the amplitude variation process, the balance point is lost, and the maintenance of the amplitude variation mechanism is difficult to a certain extent, and when the amplitude variation mechanism is required to operate to a certain amplitude during maintenance, the brake or the rack device can be opened by adopting the external additional lever protection (the amplitude variation mechanism can automatically keep balance at the balance point position without additionally installing an external protection lever, so that the maintenance difficulty and the maintenance period are greatly reduced).
Therefore, the current conditions and problems existing in the industry are:
the selection of the hinge point of the four-bar linkage structure needs higher professional technical level and stronger theoretical calculation skill, and is influenced by factors such as coefficients and experience, the results calculated by different people or under different conditions may have different conditions, and the difference is millicenti and paradox, so that the results caused by the conditions are not only uneven stress of the four-bar linkage structure and poor stability, but also increase of the fatigue coefficient of the steel structure of the four-bar linkage door machine equipment is bound to be caused, the service life of the equipment is shortened, and the general technicians in the wharf cannot verify the data sizes of the hinge point of the four-bar linkage structure, the counterweight parameters and the like. Although the inclination angle sensor for measuring the amplitude variation angle is arranged at the lower hinge point of the four-bar arm support, and based on the linear relation between the amplitude variation angle and the amplitude variation amplitude, a driver can observe and apply information fed back by the sensor in real time when operating an amplitude variation instruction, but the driver or a maintenance worker cannot judge which amplitude value is the balance point position of the mechanism according to the feedback of the sensor. Therefore, a common technician can only verify the parameters of the amplitude, the speed and the load of the mechanism and approve the equipment after the requirements are met.
Disclosure of Invention
Aiming at the technical problems described in the background art, the invention aims to design a method for automatically reading the balance point of the four-bar linkage mechanism of the portal crane, and the judgment on whether the four-bar linkage mechanism of the portal crane has the balance point and the position of the balance point is realized through relatively simple and convenient operation, so that a more scientific and effective basis is provided for general technicians to reversely detect whether the selection of the hinge point of the four-bar linkage mechanism is accurate and reversely verify whether the weight of a balance weight is reasonable.
The technical scheme of the invention is as follows:
a method for automatically reading balance points of a four-bar linkage mechanism of a gantry crane is characterized by comprising the following steps:
s1: an absolute value encoder is arranged on a transmission shaft of a four-connecting-rod portal jib luffing mechanism and is connected with a PLC system, and an angular displacement signal of the transmission shaft is fed back to the PLC system;
the PLC system obtains a real-time measurement result of the amplitude value of the amplitude mechanism based on the fixed variable relation between the angular displacement of the transmission shaft and the amplitude value of the amplitude mechanism;
s2: the waveform display unit is used for displaying the waveform corresponding to the output torque of the variable-amplitude motor, recording the oscillogram of the output torque of the variable-amplitude motor and sending the oscillogram to the PLC system in the amplitude variation process of amplitude increase or amplitude reduction of the variable-amplitude mechanism, and the PLC system is used for finishing the following judgment:
if the waveform of the output torque of the variable-amplitude motor changes between a positive value and a negative value and a moment point of the output torque of 0 appears, judging that the variable-amplitude process passes through a balance point, otherwise, judging that the variable-amplitude process does not pass through the balance point; and when the output torque of the variable amplitude motor is 0, the amplitude value measured by the absolute value encoder is the amplitude value of the four-bar linkage mechanism at the balance point.
On the basis of the above scheme, a further improved or preferred scheme further comprises:
further, the method also comprises the following steps:
s3: a calibration mechanism is installed to check the measurement precision of the absolute value encoder;
the calibration mechanism comprises a distance sensor and a target reference object matched with the distance sensor, the target reference object is fixedly arranged on the amplitude variation rack, the distance sensor is connected with the PLC system, and the following judgment is completed through the PLC system:
and when the target reference object is sensed by the distance sensor to appear at a preset specific position, the theoretical amplitude value of the amplitude varying mechanism is M, the amplitude value measured by the absolute value encoder is N, if N is consistent with M, the measurement result of the absolute value encoder is judged to be accurate, otherwise, the measurement error of the absolute value encoder is judged to appear.
Furthermore, a variable amplitude reducer is arranged in a transmission mechanism connecting an output shaft of the variable amplitude motor and the variable amplitude rack, and the absolute value encoder is preferably arranged at the low-speed end of the transmission mechanism.
Further, the target reference object is arranged in the middle of the amplitude variation rack so as to ensure that the target reference object can be detected in each amplitude variation process.
The invention has the beneficial effects that:
on the basis of additionally arranging components such as an absolute value encoder and the like, the method can realize reading of the balance point of the four-connecting-rod structure of the gantry crane by acquiring real-time signals of absolute value encoder data and motor output torque information through a PLC (programmable logic controller) system and performing simple comparison and calculation, thereby providing more effective and scientific basis for technicians, particularly common technicians, to reversely detect whether the selection of the hinge point of the four-connecting-rod structure is accurate, reversely verify whether the weight of the balance weight is reasonable, and providing convenience for searching the balance point of the mechanism in the maintenance work of the gantry crane. The method has the advantages of automatic control in the whole process, low implementation cost, high intelligent degree and strong practicability, and greatly improves the safety of the operation of the crane equipment and the convenience of the inspection work.
Drawings
FIG. 1 is a structural diagram of a four-bar linkage structure of a four-bar linkage type seat frame;
FIG. 2 is a schematic diagram of the process of amplitude variation of a four-bar linkage mechanism driven by an amplitude variation motor;
FIG. 3 is a schematic view of the mounting of a luffing mechanism tilt sensor;
FIG. 4 is a schematic top view of a horn of the present invention;
FIG. 5 is a schematic side view of a horn of the present invention;
FIG. 6 is a waveform diagram of the attenuation process of the horn at idle;
FIG. 7 is a waveform diagram of the amplification process of the horn at idle;
FIG. 8 is a waveform of the horn dampening process under heavy load;
FIG. 9 is a waveform diagram of the amplitude-increasing process of the amplitude-changing mechanism under heavy load;
FIG. 10 is a flow chart of a process for reading a motor current torque waveform;
FIG. 11 is a graph of amplitude values when reading equilibrium point locations.
In the upper diagram:
1. a large pull rod system; 2. a balance weight system 2; 3. an upper column transfer system; 4. driving a hinge point; 5. a luffing mechanism; 6. a cantilever system; 7. the trunk system; 8. a four-bar linkage structure hinge point; 9. a tilt sensor;
5-1, a target reference; 5-2, a variable amplitude rack; 5-3, a luffing mechanism brake; 5-4, a variable amplitude motor; 5-5, variable amplitude reducer; 5-6, a cam limiting mechanism; 5-7, absolute value encoder.
Detailed Description
The present invention will now be described in further detail with reference to the accompanying drawings.
As shown in fig. 1, the standard conventional configuration of the four-link gantry crane includes a large drawbar system 1, a balance weight system 2, an upper rotary column system 3, a luffing mechanism 5, a jib system 6 and 7, a trunk system, and the like. In the process of amplitude variation of the amplitude variation mechanism 5, the amplitude variation motor 5-4 drives the amplitude variation reducer 5-5, the amplitude variation reducer 5-5 drives the amplitude variation rack 5-2 to move back and forth, and the amplitude variation rack 5-2 drives the four-bar linkage to move and change through the driving hinge point 4 at the end part of the amplitude variation rack to realize the back and forth displacement of the cargo of the lifting hook, thereby completing the loading and unloading process of the cargo from a ship to a wharf or from the wharf to the ship. In order to ensure the safe operation of the system, the amplitude variation mechanism 5 is also provided with an amplitude variation mechanism brake 5-3 and a cam limiting mechanism 5-6 for limiting the stroke of the amplitude variation rack 5-2.
The invention discloses a method for automatically reading balance points of a four-bar linkage mechanism of a portal crane, which comprises the following specific implementation processes of:
s1: an absolute value encoder 5-7 is arranged on a transmission shaft of a four-connecting-rod type door seat machine amplitude variation mechanism 5, the absolute value encoder 5-7 is connected with a PLC system, and an angular displacement signal of the transmission shaft is fed back to the PLC system;
the PLC system obtains a real-time measurement result of the amplitude value of the amplitude varying mechanism 5 based on the fixed variable relation between the angular displacement of the transmission shaft and the amplitude value of the amplitude varying mechanism 5;
s2: the waveform corresponding to the output torque of the variable amplitude motor 5-4 is displayed through the waveform display unit, the waveform chart of the output torque of the variable amplitude motor 5-4 is recorded and sent to the PLC system in the amplitude variation process of amplitude increase or amplitude reduction of the variable amplitude mechanism, and the following judgment is completed through the PLC system:
if the waveform of the output torque of the variable-amplitude motor 5-4 changes between a positive value and a negative value and a moment point of the output torque of 0 appears, judging that the variable-amplitude process passes through a balance point, otherwise, judging that the variable-amplitude process does not pass through the balance point; and when the output torque of the variable amplitude motor 5-4 is 0, the amplitude value measured by the absolute value encoder 5-7 is the amplitude value of the four-bar linkage mechanism at the balance point.
S3: a calibration mechanism is installed to check the measurement precision of the absolute value encoders 5-7;
the calibration mechanism comprises a distance sensor and a target reference object 5-1 matched with the distance sensor, the target reference object 5-1 is fixedly arranged on the amplitude variation rack 5-2, the distance sensor is connected with the PLC system, and the following judgment is completed through the PLC system:
when the target reference object 5-1 is sensed by the distance sensor to appear at a preset specific position, the theoretical amplitude value of the amplitude changing mechanism 5 is set to be M, the amplitude value measured by the absolute value encoder is set to be N, if the N is consistent with the M, the measurement result of the absolute value encoder is determined to be accurate, otherwise, the measurement error of the absolute value encoder is determined to be required to be adjusted or replaced.
In the implementation process:
a variable amplitude reducer 5-5 is arranged in a transmission mechanism connecting an output shaft of the variable amplitude motor 5-4 and the variable amplitude rack 5-2, and the absolute value encoder 5-7 is preferably arranged at the low-speed end of the transmission mechanism.
The variable amplitude motor 5-4 is a variable frequency motor, and the torque output by the variable amplitude motor 5-4 can be directly read out from the parameters displayed by the display panel of the frequency converter. However, when the amplitude-changing mechanism 5 runs, the change speed fluctuation of the real-time current and the real-time output torque of the amplitude-changing motor 5-4 is too fast, and the change cannot be seen clearly by eyes, so the parameters are recorded through a oscillogram, and the research and the viewing are convenient.
The distance sensor can adopt a contact type sensor, the target reference object 5-1 can be a component fixedly arranged on the amplitude variation rack 5-2, and when the target reference object 5-1 touches the contact type sensor, the contact type sensor sends a sensing signal to the PLC system to trigger the PLC system to start analyzing and comparing. For example, according to a predetermined design, when the target reference object 5-1 touches the touch sensor during the forward or backward movement of the horn rack 5-2, the theoretical amplitude value of the horn rack 5 should be "25.0 m amplitude", and the PLC system reads the signal sent by the absolute encoder 5-7, and if the measured signal obtained by the absolute encoder 5-7 is also "25.0 m amplitude", it indicates that the data of the absolute encoder 5-7 is accurate, and if the data fed back by the absolute encoder 5-7 is not "25.0 m amplitude", such as "24.8 m" or "25.2 m", it indicates that the absolute encoder 5-7 has an error and needs to be adjusted or replaced.
By this calibration step it is ensured that the absolute value encoder 5-7 does not show accumulated errors after a long run. The target reference object 5-1 can be generally arranged in the middle of the amplitude variation rack 5-2, so that the target reference object 5-1 can be sensed when each amplitude variation process is operated.
The method automatically reads and records the amplitude value at the moment of the amplitude-variable balance point, and can be used for verifying whether the hinge point and the counterweight weight of the four-bar linkage structural member are proper or not. Aiming at the portal jib crane which is already put into use, if no balance point exists in the whole amplitude variation process under the condition of no load or heavy load, the portal jib crane does not influence the normal use, but the energy consumption of the amplitude variation motor and the stress strength of a steel structure need to be increased. The automatic reading of the balance point can be used as the basis and feedback for improving the performance of the equipment and increasing the stress stability of the structure, and configuring weight debugging.
Test verification:
the balance point is automatically read by using a gantry crane which is inspected by other methods to carry out a no-load or heavy-load test. The test included two amplitude-varying processes, a maximum amplitude-decreasing process to a minimum amplitude and an amplitude-increasing process from a minimum amplitude to a maximum amplitude. The amplitude reduction/amplification process has a balance point under the no-load condition and a balance point under the heavy load condition respectively.
a. Under the condition of no load:
under the condition that the lifting hook does not lift a load, a driver operates a handle instruction of the amplitude-changing mechanism to start a state that the arm support starts to reduce amplitude at full speed at the maximum amplitude or starts to increase amplitude at full speed at the minimum amplitude, as shown in fig. 2, in the whole operation process of amplitude change, the frequency converter reads the real-time output torque of the amplitude-changing motor in a profibus DP communication state font mode and displays the real-time output torque in a waveform graph mode. The waveform of amplitude reduction under no-load of the output torque of the amplitude-changing motor is shown in fig. 6, and the waveform of amplitude increase under no-load of the output torque of the amplitude-changing motor is shown in fig. 7. The curved letters in fig. 6 and 7 represent a: a driver gives an instruction to the variable amplitude motor for speed; b, the actual running speed of the variable amplitude motor; c: feeding back current when the variable amplitude motor actually operates; d, the torque of the variable amplitude motor; e: the torque of the amplitude variation motor is at a zero moment position.
b. Under the heavy load condition:
under the condition that a hook of the portal crane lifts rated load (40 t goods), a driver operates a handle instruction of the amplitude-changing mechanism to enable the arm support to start full-speed amplitude reduction at the maximum amplitude or to start full-speed amplitude increase at the minimum amplitude, and in the whole operation process of amplitude change, the frequency converter reads the real-time output torque of the amplitude-changing motor in a profibus DP state character form and displays the real-time output torque in a waveform graph form.
The amplitude-reducing wave form under the heavy load of the output torque of the amplitude-changing motor is shown in fig. 8, and the amplitude-increasing wave form under the heavy load of the output torque of the amplitude-changing motor is shown in fig. 9. The curve letters in fig. 8 and 9 represent a: a driver gives an instruction to the variable amplitude motor for speed; b, the actual running speed of the variable amplitude motor; c: feeding back current when the variable amplitude motor actually operates; d, the torque of the variable amplitude motor; e: the torque of the amplitude variation motor is at a zero moment position.
As can be seen from the waveform diagrams of fig. 6 to 9, the parameters of the current, the output torque, the mechanism speed and the like of each variable amplitude motor change greatly 4 seconds before the variable amplitude mechanism is started; within the acceleration and deceleration time range, the output current and the torque of the variable amplitude motor tend to be stable after 4 seconds; at the position of the E point, no matter in the amplitude increasing process or the amplitude decreasing process, the four-bar structure reaches the position of a balance point, and the output torque is zero at the moment. When the amplitude variation mechanism is at the amplitude position, the whole four-bar linkage mechanism is in a balanced state, and the state of the whole structure is the most stable. The design of the four-bar linkage completely meets the design specification requirement.
When the output torque of the variable amplitude motor is positive, the variable amplitude motor drives the four-bar structure to change the amplitude of the variable amplitude motor through the output power, and at the moment, the variable amplitude motor is in an energy consumption state, and the more the output power is, the more the energy consumption is; when the output torque of the variable amplitude motor is negative, the output torque indicates that the output torque is changed into kinetic energy with variable amplitude through the gravity of goods or the gravitational potential energy of the weight of the counterweight, the variable amplitude motor is in a power generation state to generate electric energy, the generated electric energy is converted into heat energy through an external resistor disc to be released, and when the potential energy is more converted into amplitude kinetic energy, the situation that the goods at the front end are too heavy and the counterweight is too light is indicated; or vice versa, leading to structural imbalance; therefore, whether the load is under the condition of no load or heavy load, the process of torque positive and negative alternation occurs once in the whole amplitude variation process, and the verification of the four-bar linkage balance design and the requirement of the steel structure design meeting the specification can be shown.
If the output torque of the amplitude variation motor is not zero, the situation shows that the whole amplitude variation process of the amplitude variation mechanism does not pass through a balance point, the situation shows that the position of the four-bar structure or the counterweight load does not meet the requirement, and redesign and calculation are needed.
Because the torque changes from a positive value to a negative value or from a negative value to a positive value, the time is short, and the torque can be read only by programming, so that the PLC system takes the condition that the output torque of the variable amplitude motor is zero, reads the data of the absolute value encoder when the torque is zero instantly, and the value corresponding to the data of the encoder is the actual amplitude value of the variable amplitude. Under the condition of reasonable four-bar structure, when the crane is in no-load or heavy load, the amplitude balance points under the amplitude reduction command or the amplitude increase command are at the same position, and the amplitude value is also similar in the portal cranes of the same type. The amplitude value can be used for verifying the four-bar design and is convenient to use in dock maintenance in the future.
The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and adaptations to those skilled in the art without departing from the principles of the present invention may be apparent to those skilled in the relevant art and are intended to be within the scope of the present invention.
Claims (4)
1. A method for automatically reading balance points of a four-bar linkage mechanism of a gantry crane is characterized by comprising the following steps:
s1: an absolute value encoder (5-7) is arranged on a transmission shaft of a four-connecting-rod type portal jib luffing mechanism (5), the absolute value encoder (5-7) is connected with a PLC system, and an angular displacement signal of the transmission shaft is fed back to the PLC system;
the PLC system obtains a real-time measurement result of the amplitude value of the amplitude varying mechanism (5) based on the fixed variable relation between the angular displacement of the transmission shaft and the amplitude value of the amplitude varying mechanism (5);
s2: the waveform corresponding to the output torque of the variable amplitude motor (5-4) is displayed through the waveform display unit, a waveform diagram of the output torque of the variable amplitude motor (5-4) is recorded and sent to the PLC system in the amplitude variation process of amplitude increase or amplitude reduction of the variable amplitude mechanism, and the following judgment is completed through the PLC system:
if the waveform of the output torque of the variable amplitude motor (5-4) changes between a positive value and a negative value and a moment point of the output torque of 0 appears, judging that the variable amplitude process passes through a balance point, otherwise, judging that the variable amplitude process does not pass through the balance point; and when the output torque of the amplitude variation motor (5-4) is 0, the amplitude value measured by the absolute value encoder (5-7), namely the amplitude value of the four-bar linkage mechanism at the balance point.
2. The method for automatically reading the balance point of the four-bar linkage mechanism of the gantry crane according to claim 1, further comprising the following steps:
s3: a calibration mechanism is arranged to verify the measurement accuracy of the absolute value encoder (5-7);
the calibration mechanism comprises a distance sensor and a target reference object (5-1) matched with the distance sensor, the target reference object (5-1) is fixedly arranged on the amplitude variation rack (5-2), the distance sensor is connected with the PLC system, and the following judgment is completed through the PLC system:
and when the target reference object (5-1) is sensed by the distance sensor to appear at a preset specific position, the theoretical amplitude value of the amplitude variation mechanism (5) is M, the amplitude value measured by the absolute value encoder is N, if N is consistent with M, the measurement result of the absolute value encoder is judged to be accurate, otherwise, the measurement error of the absolute value encoder is judged to appear.
3. The method for automatically reading the balance point of the four-bar linkage mechanism of the portal crane according to claim 1 or 2, characterized in that a variable amplitude reducer (5-5) is arranged in a transmission mechanism connecting an output shaft of the variable amplitude motor (5-4) and the variable amplitude rack (5-2), and the absolute value encoder (5-7) is arranged at the low-speed end of the transmission mechanism.
4. The method for automatically reading the balance point of the four-bar linkage mechanism of the portal crane according to claim 2, wherein the target reference object (5-1) is arranged in the middle of the amplitude variation rack (5-2).
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1440596A (en) * | 1973-07-19 | 1976-06-23 | Hitachi Ltd | Electrically operated handling apparatus for a load |
| CN103213903A (en) * | 2013-05-03 | 2013-07-24 | 杭州华新机电工程有限公司 | Method and device for detecting balance point of balance weight of portal crane |
| CN110555272A (en) * | 2019-09-05 | 2019-12-10 | 上海海事大学 | Intelligent configuration system and method based on luffing mechanism of portal crane |
| CN113044721A (en) * | 2019-12-26 | 2021-06-29 | 天津港焦炭码头有限公司 | Portal crane operation attitude control system and method |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1440596A (en) * | 1973-07-19 | 1976-06-23 | Hitachi Ltd | Electrically operated handling apparatus for a load |
| CN103213903A (en) * | 2013-05-03 | 2013-07-24 | 杭州华新机电工程有限公司 | Method and device for detecting balance point of balance weight of portal crane |
| CN110555272A (en) * | 2019-09-05 | 2019-12-10 | 上海海事大学 | Intelligent configuration system and method based on luffing mechanism of portal crane |
| CN113044721A (en) * | 2019-12-26 | 2021-06-29 | 天津港焦炭码头有限公司 | Portal crane operation attitude control system and method |
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