AU2017400814A1 - On-line monitoring system and method for suspension steel wire rope for hoisting container - Google Patents
On-line monitoring system and method for suspension steel wire rope for hoisting container Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66B—ELEVATORS; ESCALATORS OR MOVING WALKWAYS
- B66B5/00—Applications of checking, fault-correcting, or safety devices in elevators
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Abstract
An on-line monitoring system and method for a suspension steel wire rope for a hoisting container. The system comprises: a first sensing unit, a container top relay device, a wellhead receiving relay device, an analysis gateway, and a data display and analysis processing platform. The first sensing unit is used for real-time acquisition of a first state parameter capable of characterizing a suspension steel wire rope; the container top relay device is disposed at the top of a hoisting container and electrically connected to the first sensing unit, and is used for receiving the first state parameter acquired by the first sensing unit, and transmitting the first state parameter to the wellhead receiving relay device by means of frequency hopping and spreading and time division multiple access wireless technology; the wellhead receiving relay device is disposed on the inner wall of a shaft or at a wellhead and used for transmitting the received data to the data display and analysis processing platform by means of the analysis gateway to facilitate display, analysis, and processing of the data. The method can achieve real-time uninterrupted monitoring of a suspension steel wire rope for a hoisting container during periodic operation, and ensure the reliability and security of a hoisting system in a deep well environment.
Description
The disclosure relates to the field of safety monitoring, and particularly to an online monitoring system and method applied for suspension steel wire ropes of a hoisting container in a deep well environment.
BACKGROUND
In a deep well environment (for example, an elevator well, a mine well and the like), a fitting mechanism of a drum and a suspension steel wire rope is usually adopted to drive a hoisting container (for example, an elevator car, a cage and the like) to ascend and descend. While monitoring a service state of the suspension steel wire rope is crucial for safe operation of the hoisting container.
Existing suspension steel wire rope monitoring includes tension monitoring, transverse vibration signal monitoring and the like. For example, in a Chinese utility model patent No. CN203359719U: Tension Detection Device of Elevator Steel Wire Rope, the tension detection device of elevator steel wire rope is arranged at an end portion of each steel wire rope, and an oil pressure sensor on each tension detection device of elevator steel wire rope is subject to consistent pre-pressure so as to improve accuracy of a tension detection result of each steel wire rope. However, such a device is relatively effective for an elevator steel wire rope only, and for a mine well environment with a longer underground distance and using multiple balance steel wire ropes, such a tension detection device may have a great error. In addition, this solution may only perform monitoring and data collection on a steel wire rope signal, and may not implement real-time monitoring.
In a Chinese patent application No. CN105203200A: Steel Wire Rope Transverse Vibration Signal Measurement Device and Method and Transverse Vibration Monitoring Method, an adopted monitoring solution is to measure a vibration displacement signal by adopting the steel wire rope transverse vibration displacement signal measurement method, process the vibration displacement signal to obtain a vibration amplitude and a vibration frequency and then compare them with preset values to perform a crisis prevention. This solution may only monitor a transverse vibration signal, and does not consider influence of longitudinal vibration on a hoisting system.
In a word, existing technical practices and theoretical researches are generally made for monitoring of a suspension steel wire rope under a working condition that a depth of a mine well is smaller than 500m, and there are few researches made for a deep well of more than 500m. In a deep well environment of more than 500m, a signal transmission and penetration capability is poor, energy loss is relatively high, and interference is relatively great, so that it is difficult to accurately monitor a suspension steel wire rope in real time. On the other hand, emphasis is mostly laid on monitoring of a single factor, and there are no researches on monitoring of multiple factors.
SUMMARY
A purpose of the disclosure is to propose an online monitoring system and method for suspension steel wire ropes of a hoisting container, which may implement real-time discontinuous monitoring of the suspension steel wire ropes of the hoisting container during periodic operation and ensure reliability and safety of a hoisting system in a deep well environment.
In order to achieve the purpose, the disclosure provides an online monitoring system for suspension steel wire ropes of a hoisting container, which includes: a first sensing unit, a container top relay device, a wellhead receiving relay device, a parsing gateway and a data display and analysis processing platform, wherein the first sensing unit may be used for acquiring a first state parameter capable of characterizing the suspension steel wire ropes in real time; the container top relay device may be arranged at a top of the hoisting container, and may be electrically connected with the first sensing unit, so as to be used for receiving the first state parameter acquired by the first sensing unit and transmit the first state parameter to the wellhead receiving relay device by virtue of a frequency modulation spread spectrum and time division multiple wireless technology; and the wellhead receiving relay device may be arranged on an inner wall of a wellbore or at a wellhead, so as to be used for sending received data to the data display and analysis processing platform via the parsing gateway for data display, analysis and processing.
Furthermore, data transmission between the wellhead receiving relay device and the parsing gateway is performed in a frequency-hopping communication manner.
Furthermore, the first sensing unit may include multiple oil pressure sensors, arranged on bypasses of balancing oil cylinders corresponding to each suspension steel wire rope on a steel wire rope tension hydraulic automatic balancing device at the top of the hoisting container respectively and used for acquiring oil pressure signals of the corresponding balancing oil cylinders.
Furthermore, the first sensing unit may include multiple vibration sensors, arranged at transverse and longitudinal positions of each suspension steel wire rope on the steel wire rope tension hydraulic automatic balancing device at the top of the hoisting container respectively and used for acquiring transverse and longitudinal vibration signals of the suspension steel wire ropes.
Furthermore, the system may further include a second sensing unit arranged on or around a hoisting drum of the hoisting container, electrically connected with the wellhead receiving relay device and used for acquiring a second state parameter capable of characterizing rotation turns of the hoisting drum and transmit the second state parameter to the wellhead receiving relay device.
Furthermore, the second sensing unit may include a double-hall sensor, and two steel magnets of the double-hall sensor may be symmetrically arranged on two sides of a rotating shaft of the hoisting drum, and may be used for acquiring measured pulse signals.
Furthermore, the first sensing unit may include multiple oil pressure sensors and multiple vibration sensors, the multiple oil pressure sensors may be arranged on the bypasses of the balancing oil cylinders corresponding to each suspension steel wire rope on the steel wire rope tension hydraulic automatic balancing device at the top of the hoisting container respectively, and may be used for acquiring the oil pressure signals of the corresponding balancing oil cylinders, and the multiple vibration sensors may be arranged at the transverse and longitudinal positions of each suspension steel wire rope on the steel wire rope tension hydraulic automatic balancing device at the top of the hoisting container respectively, and may be used for acquiring the transverse and longitudinal vibration signals of the suspension steel wire ropes; and data transmission between the wellhead receiving relay device and the parsing gateway is performed in the frequency-hopping communication manner.
Furthermore, an explosion-proof and intrinsic safety type power box may further be arranged at the top of the hoisting container, and may be used for supplying power to the first sensing unit and the container top relay device; and the container top relay device may be an intrinsic safety type acquisition and sending box, and the wellhead receiving relay device may be an intrinsic safety type wireless receiving box.
Furthermore, the data display and analysis processing platform may include: an oil pressure data receiving module, used for receiving parsed oil pressure data sent by the parsing gateway;
a tension value calculation module, used for calculating tension values of the corresponding suspension steel wire ropes according to the oil pressure data; and a first failure indication module, used for calculating a tension unbalance degree, impact loads, hoisting loads or oil pressure changes of the suspension steel wire ropes according to the oil pressure data and the tension values, and performing display and failure indication according to preset threshold values.
Furthermore, the data display and analysis processing platform may include: a pulse data receiving module, used for receiving parsed pulse data sent by the parsing gateway;
a descent depth calculation module, used for calculating a descent depth of the hoisting container according to the pulse data; and a depth display module, used for displaying the descent depth of the hoisting container in real time.
Furthermore, the data display and analysis processing platform may include: a vibration data receiving module, used for receiving parsed vibration data sent by the parsing gateway;
a spectrogram obtaining module, used for calculating vibration displacement diagrams of the corresponding suspension steel wire ropes according to the vibration data, and obtaining spectrograms by fast Fourier transform; and a second failure indication module, used for judging whether a vibration displacement exceeds a limit or not or whether an external excitation frequency is approximate to an intrinsic frequency of the hoisting container or not according to a preset threshold value, and performing display and failure indication.
Furthermore, the container top relay device may further be used for transmitting a power parameter of the explosion-proof and intrinsic safety type power box to the wellhead receiving relay device; and the data display and analysis processing platform may include: a power data receiving module, used for receiving parsed power data sent by the parsing gateway, and a power alarming module, used for judging whether power is insufficient or not according to a preset threshold value, and performing display and failure indication.
In order to achieve the purpose, the disclosure provides an online monitoring method for the online monitoring system for the suspension steel wire ropes of the hoisting container, which may include that:
a first sensing unit acquires a first state parameter capable of characterizing the suspension steel wire ropes in real time, and transmits it to a container top relay device;
the container top relay device receives the first state parameter acquired by the sensing unit, and transmits the first state parameter to the wellhead receiving relay device by virtue of a frequency modulation spread spectrum and time division multiple wireless technology; and the wellhead receiving relay device sends received data to a data display and analysis processing platform via the parsing gateway for data display, analysis and processing.
Furthermore, the operation that the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway may specifically include that:
the wellhead receiving relay device transmits the received data to the parsing gateway in a frequency modulation communication manner; and the parsing gateway parses the received data, and sends it to the data display and analysis processing platform.
Furthermore, the first state parameter may include oil pressure signals of balancing oil cylinders corresponding to each suspension steel wire rope on a steel wire rope tension hydraulic automatic balancing device arranged at a top of the hoisting container respectively.
Furthermore, the first state parameter may include transverse and longitudinal vibration signals of each suspension steel wire rope on the steel wire rope tension hydraulic automatic balancing device arranged at the top of the hoisting container respectively.
Furthermore, the online monitoring system for the suspension steel wire ropes of the hoisting container may further include a second sensing unit arranged on or around a hoisting drum of the hoisting container and electrically connected with the wellhead receiving relay device, and before the operation that the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the online monitoring method may further include that:
the second sensing unit acquires a second state parameter capable of characterizing rotation turns of the hoisting drum in real time, and transmits the second state parameter to the wellhead receiving relay device.
Furthermore, the second state parameter may include pulse signals acquired and measured by two steel magnets of a double-hall sensor symmetrically arranged on two sides of a rotating shaft of the hoisting drum.
Furthermore, after the operation that the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the method may further include that:
the data display and analysis processing platform receives parsed oil pressure data sent by the parsing gateway, and calculates tension values of the corresponding suspension steel wire ropes according to the oil pressure data; and the data display and analysis processing platform calculates a tension unbalance degree, impact loads, hoisting loads or oil pressure changes of the suspension steel wire ropes according to the oil pressure data and the tension values, and performs display and failure indication according to preset threshold values.
Furthermore, after the operation that the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the method may further include that:
the data display and analysis processing platform receives parsed pulse data sent by the parsing gateway, and calculates a descent depth of the hoisting container according to the pulse data; and the data display and analysis processing platform displays the descent depth of the hoisting container in real time.
Furthermore, after the operation that the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the method may further include that:
the data display and analysis processing platform receives parsed vibration data sent by the parsing gateway, calculates vibration displacement diagrams of the corresponding suspension steel wire ropes according to the vibration data, and obtains spectrograms by fast Fourier transform; and the data display and analysis processing platform judges whether a vibration displacement exceeds a limit or not or whether an external excitation frequency is approximate to an intrinsic frequency of the hoisting container or not according to a preset threshold value, and performs display and failure indication.
Furthermore, an explosion-proof and intrinsic safety type power box may further be arranged at the top of the hoisting container, and may be used for supplying power to the first sensing unit and the container top relay device, and the online monitoring method may further include that:
the container top relay device transmits a power parameter of the explosionproof and intrinsic safety type power box to the wellhead receiving relay device; and the data display and analysis processing platform receives parsed power data sent by the parsing gateway, judges whether power is insufficient or not according to a preset threshold value, and performs display and failure indication.
On the basis of the technical solutions, according to the disclosure, the container top relay device arranged at the top of the hoisting container receives the state parameter acquired by the first sensing unit in real time and characterizing the suspension steel wire ropes to implement real-time continuous monitoring of the suspension steel wire ropes of the hoisting container during periodic operation; and moreover, data is transmitted to the wellhead receiving relay device by virtue of the frequency modulation spread spectrum and time division multiple wireless technology, and since a wireless communication manner adopted for data transmission has higher stability and anti-interference performance and a better longdistance transmission, the online monitoring system for a deep well environment is endowed with higher reliability and safety.
BRIEF DESCRIPTION OF DRAWINGS
The drawings described here are used for providing a further understanding to the disclosure, and form a part of the application. Schematic embodiments of the disclosure and the description thereof are used for explaining the disclosure and are not intended to form improper limits to the disclosure. In the drawings:
FIG. 1 is a schematic diagram of an embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 2 is a schematic diagram of another embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 3 is a schematic diagram of another embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 4 is a structure arrangement diagram of an embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 5 is an arrangement diagram of vibration sensors in an embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 6 is an arrangement diagram of oil pressure sensors in an embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 7 is a schematic diagram of a frequency-hopping communication manner in an embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure.
FIG. 8 is a flowchart of an embodiment of an online monitoring method according to the disclosure.
FIG. 9 is a flowchart of another embodiment of an online monitoring method according to the disclosure.
FIG. 10 is a flowchart of receiving and processing oil pressure data in an embodiment of an online monitoring method according to the disclosure.
FIG. 11 is a flowchart of receiving and processing pulse data in an embodiment of an online monitoring method according to the disclosure.
FIG. 12 is a flowchart of receiving and processing vibration data in an embodiment of an online monitoring method according to the disclosure.
DETAILED DESCRIPTION
The technical solutions of the disclosure will further be described below through the drawings and embodiments in detail.
FIG. 1 is a schematic diagram of an embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure. In combination with arrangement diagrams shown in FIGS. 4-6, the online monitoring system for the suspension steel wire ropes of the hoisting container in the embodiment includes: a first sensing unit 10, a container top relay device 20, a wellhead receiving relay device 30, a parsing gateway 40 and a data display and analysis processing platform 50.
The first sensing unit 10 is used for acquiring a first state parameter capable of characterizing the suspension steel wire ropes 3 in real time, wherein the first sensing unit 10 may include multiple oil pressure sensors 11, arranged on bypasses of balancing oil cylinders corresponding to each suspension steel wire rope 3 on a steel wire rope tension hydraulic automatic balancing device 2 at the top of the hoisting container 1 respectively and used for acquiring oil pressure signals of the corresponding balancing oil cylinders. The acquired oil pressure signals may be converted into tension values of the corresponding suspension steel wire ropes according to pressure bearing areas of pistons of the balancing oil cylinders in a subsequent processing link, and tension differences between multiple suspension steel wire ropes are further calculated, so that an accurate and effective monitoring result may be obtained without damaging a structure and stability of a hoisting system.
For example, an Analogue/Digital (A/D) conversion reference voltage VREF set in the online monitoring system for the suspension steel wire ropes of the hoisting container is x V, conversion accuracy is 12 bits, it is set that voltage signals after output signals of the tension oil pressure sensors are conditioned is Vin and conversion results are ADC, and then:
HDC =x 4096 v y REF (!)
V _ ADC* _ ADC* x 1N ” 4096 ” 4096 (2).
A range of the oil pressure sensor is 0~p MPa, a corresponding voltage after an output current signal passes through precision resistance is y~z V, it is set that a monitored oil pressure magnitude is P, of which a unit is MPa, and then:
p Af-y p z (3) and Vin is substituted to obtain „ JDCxx-4096j\ P = px (--)
4096z (4).
It is set that the pressure bearing area of the piston of the balancing oil cylinder is S cm , and then a calculation formula for a tension F of the suspension steel wire rope is:
F = PS
ADC* x-4096k 6 4 = »x (--)x Sx 10 x 10
4096z
ADC* x-4096k 2 = p* (--)* 5x10
4096z (5).
The first sensing unit 10 may further include multiple vibration sensors 12, arranged at transverse and longitudinal positions of each suspension steel wire rope 3 on the steel wire rope tension hydraulic automatic balancing device 2 at the top of the hoisting container 1 respectively and used for acquiring transverse and longitudinal vibration signals of the suspension steel wire ropes 3. Transverse and longitudinal vibration signals of the suspension steel wire ropes 3 may be monitored to more comprehensively inspect influence of vibration of the suspension steel wire ropes 3 in vibration planes perpendicular to extending directions on a vibration amplitude of the hoisting system and to be able of determining whether exists a probability of resonance or not.
The vibration signals generated by the suspension steel wire ropes in an operation process are received by the vibration sensors (for example, vibration acceleration sensors and the like), vibration displacement diagrams of the suspension steel wire ropes may be obtained by integration estimation, and then spectrograms are obtained by fast Fourier transform. There is made such a hypothesis that a joint of the hoisting container and the steel wire rope is an origin of coordinates, a downward direction is a positive direction, a length l(t) of the suspension steel wire rope changes over time t, and a linear density is p. H is a maximum height by which the hoisting container is allowed to be hoisted, a length of a balancing steel wire rope is H-l(t), and changes over the time t, and a linear density is p2. A mass of the hoisting container is m, and from a basic formula me = m + (H — l(t))p2 of an equivalent mass me of the hoisting container and the steel wire rope, it can be seen that the equivalent mass me keeps changing under influence of the balancing steel wire rope in an operation process of the hoisting steel wire rope in a deep well, so that an intrinsic frequency of the hoisting container also changes, and the obtained spectrogram may further monitor influence of an external excitation frequency on the vibration amplitude of the system and the probability of resonance in real time.
In the embodiment shown in FIG. 4, the first sensing unit 10 may include both the oil pressure sensors 1 and the vibration sensors 12 as described above to implement real-time monitoring of tensions and vibration conditions of the suspension steel wire ropes 3. In other embodiments, the first state parameter characterizing the suspension steel wire ropes 3 is not limited to oil pressure and vibration parameters as described above, and may further include other parameters, such as a tension parameter. Correspondingly, the first sensing unit 10 may further include any other sensing unit capable of acquiring a state parameter characterizing the suspension steel wire ropes 3 such as a tension sensor and the like.
Referring to FIG. 4, the container top relay device 20 is arranged at the top of the hoisting container 1, and is electrically connected with the first sensing unit 10, so as to be used for receiving the first state parameter acquired by the first sensing unit 10. The first state parameter is transmitted between the container top relay device 20 and the wellhead receiving relay device 30 in a wireless communication manner. For a deep well environment such as a mine well, an elevator well and the like, multiple factors such as a relatively large well depth, interference of facilities in the well and the like may seriously restrict outward transmission of sensing signals and easily cause the problem of signal distortion. While in the embodiment, the first state parameter may be transmitted to the wellhead receiving relay device 30 by virtue of a frequency modulation spread spectrum and time division multiple wireless technology. Since such a wireless communication manner adopted for data transmission has higher stability and anti-interference performance and a better longdistance transmission characteristic (for example, a transmission distance is more than 3.2 km), the online monitoring system in the deep well environment is endowed with higher reliability and safety.
The wellhead receiving relay device 30 is arranged on an inner wall of a wellbore or at a wellhead, and is used for sending received data to the data display and analysis processing platform 50 via the parsing gateway 40 for data display, analysis and processing. Considering that the wellhead receiving relay device 30 may be required to send multiple state parameters to the parsing gateway and accuracy of a monitoring result may be influenced in case of interference in a transmission process, data transmission is preferably performed between the wellhead receiving relay device 30 and the parsing gateway 40 by adopting a frequency-hopping communication manner.
Frequency-hopping communication is a communication manner where signal transmission carrier frequencies of receiving and sending parties discretely change according to a predetermined rule, that is, the carrier frequencies used in the communication are randomly hopped under control of pseudo-random change codes. Compared with fixed-frequency communication, the frequency-hopping communication manner has a high anti-interference capability, and even if a part of frequency points is interfered, communication may still be normally performed on other frequency points which are not interfered.
When frequency-hopping communication is applied to implement data transmission from the wellhead receiving relay device 30 to the parsing gateway 40 in the embodiment, referring to FIG. 7, a frequency synthesizer on a sending side controls a frequency of an output carrier signal according to a frequency-hopping instruction sent by a frequency-hopping instruction generator. Correspondingly, along with continuous instruction sending of the frequency-hopping instruction generator, the frequency synthesizer is controlled to continuously change the frequency of its output carrier, and then a modulated carrier frequency output by a frequency mixer may also be continuously hopped along with instructions, thereby switching the sensing signal into different data transmission channels for transmission according to a frequency-hopping sequence. After a receiving side receives the data, original data may be obtained by processing according to the same frequency-hopping sequence as the sending side.
Besides the state parameter from the suspension steel wire ropes, monitoring of a depth where the hoisting container is located may further be implemented in the online monitoring system for the suspension steel wire ropes of the hoisting container. FIG. 2 is a schematic diagram of another embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure. The embodiment further includes a second sensing unit 60 arranged on or around a hoisting drum 4 of the hoisting container 1, compared with the abovementioned embodiment. The second sensing unit 60 is electrically connected with the wellhead receiving relay device 30, and is used for acquiring a second state parameter capable of characterizing rotation turns of the hoisting drum, and transmits the second state parameter to the wellhead receiving relay device 30. The second sensing unit 60 may include a double-hall sensor, and two steel magnets of the double-hall sensor are symmetrically arranged on two sides of a rotating shaft of the hoisting drum 4, and are used for acquiring measured pulse signals. When the rotating shaft of the hoisting drum 4 rotates, the number of rotation turns of the drum may be calculated according to a number of pulses measured by the double-hall sensor and a rotating direction of the drum, lengths of the suspension steel wire ropes 3 led from the hoisting drum 4 may be determined, and a specific descent depth position of the hoisting container 1 in the deep well environment 5 is further determined.
For example, a clearance between the two steel magnets of the double-hall sensor is about 8mm, and a marker line is arranged along a rotating direction of the steel magnets. When the number of the measured pulses is n and a diameter of the hoisting drum 4 is d, the descent depth S of the hoisting container 1 may be calculated according to the following formula example:
S = nx—x πχd 2 (6).
FIG. 3 is a schematic diagram of another embodiment of an online monitoring system for suspension steel wire ropes of a hoisting container according to the disclosure. A power box 70 is further arranged at the top of the hoisting container 1 in the embodiment, and is used for supplying power to the first sensing unit 10 and the container top relay device 20, compared with each abovementioned system embodiment. For a mine well environment with an explosion risk, the power box 70 preferably adopts an explosion-proof and intrinsic safety type power box which is provided with an explosion-proof casing and of which a circuit is partially of an intrinsic safety type. The container top relay device 20 preferably adopts an intrinsic safety type acquisition and sending box of which a circuit is completely intrinsically safe, and the wellhead receiving relay device 30 preferably adopts an intrinsic safety type wireless receiving box of which a circuit is completely intrinsically safe.
In each abovementioned system embodiment, the data display and analysis processing platform 50 may be implemented by adopting one or more servers, universal computers, industrial control computers or the like. Multiple pieces of monitoring and analysis software may be run in the data display and analysis processing platform 50 to implement corresponding data processing functions.
For the embodiment where the first sensing unit 10 includes the multiple oil pressure sensors 11, the oil pressure signals, acquired by the oil pressure sensors 11, of the balancing oil cylinders reach the data display and analysis processing platform 50 through the container top relay device 20, the wellhead receiving relay device 30 and the parsing gateway 40. Correspondingly, the data display and analysis processing platform 50 may specifically include: an oil pressure data receiving module, a tension value calculation module and a first failure indication module. The oil pressure data receiving module is used for receiving parsed oil pressure data sent by the parsing gateway 40, the oil pressure data corresponding to the oil pressure signals acquired by the oil pressure sensors 11. The tension value calculation module is used for calculating tension values of the corresponding suspension steel wire ropes 3 according to the oil pressure data, a specific calculation process referring to the abovementioned example and calculation formula. The first failure indication module is used for calculate a tension unbalance degree, impact loads, hoisting loads or oil pressure changes of the suspension steel wire ropes 3 according to the oil pressure data and the tension values, and perform display and failure indication according to preset threshold values.
For example, the first failure indication module may realize the following functions.
A: tension unbalance alarming and unbalance degree indication
For example, when the hoisting container (for example, a skip/cage and the like) is hoisted by adopting 4 suspension steel wire ropes, a tension unbalance degree B of the suspension steel wire ropes may be calculated through the following formula example:
x!00% (7), where Ft is a tension value of the ith suspension steel wire rope, and i=l~4.
When the tension unbalance degree exceeds a preset threshold value (for example, 10%), an indicator lamp corresponding to a tension unbalance condition turns to red representing alarming, and an audible alarm may be given (for example, alarming sounds are continuously produced for three times). In addition, the current tension unbalance degree of the suspension steel wire ropes may also be displayed through an indicator bar of the tension unbalance degree in real time.
B: impact load
When the skip is suddenly stopped or stuck in the well and may not be hoisted, the suspension steel wire ropes may be subjected to huge impact loads, at this moment, the tension values of the suspension steel wire ropes exceed a preset safety threshold value, an indicator lamp corresponding to the impact load may turn to red representing alarming, and an audible alarm may be given (for example, continuous voice alarming sounds).
C: overload alarming
For an application scenario where the hoisting container is required to load a material, for example, in a coalmine environment, a load is calculated according to a weight after loading and a weight of the empty skip, when the load of the skip exceeds a set overload alarming value or a hoisting load is higher than a preset hoisting load threshold value, an indicator lamp corresponding to overload alarming turns to red representing alarming, and an audible alarm may be given (for example, continuous three voice alarms) to indicate a worker not to start the hoisting system in an overload state.
D: cylinder sticking alarming
If the balancing oil cylinders are stuck, oil pressure therein is kept stable and unchanged. Therefore, whether there exists a cylinder sticking condition or not is determined according to whether oil pressure changes within a preset time range are smaller than a preset threshold value or not. When it is determined that the cylinders are stuck, an indicator lamp corresponding to cylinder sticking turns to red representing alarming, and an audible alarm may be given (for example, continuous alarming sounds).
In addition, the data display and analysis processing platform 50 may further draw a tension curve of the steel wire rope according to the tension value of the suspension steel wire rope and display the curve. A vertical coordinate of the curve may adopt the tension value, and a horizontal coordinate may adopt a depth value of the hoisting container, and may also select time.
For the embodiment where the first sensing unit 10 includes the multiple vibration sensors 12, the transverse and longitudinal vibration signals acquired by the vibration sensors 12 reach the data display and analysis processing platform 50 through the container top relay device 20, the wellhead receiving relay device 30 and the parsing gateway 40. Correspondingly, the data display and analysis processing platform 50 may specifically include: a vibration data receiving module, a spectrogram obtaining module and a second failure indication module. The vibration data receiving module is used for receiving parsed vibration data sent by the parsing gateway 40. The spectrogram obtaining module is used for calculating vibration displacement diagrams of the corresponding suspension steel wire ropes 3 according to the vibration data, and obtains spectrograms by fast Fourier transform. The second failure indication module is used for judging whether a vibration displacement exceeds a limit or not or whether an external excitation frequency is approximate to an intrinsic frequency of the hoisting container 1 or not according to a preset threshold value, and performs display and failure indication.
For example, the second failure indication module may realize the following functions.
E: the calculated vibration displacement is compared with a preset threshold value to judge whether the vibration displacement exceeds the limit or not, and if it is determined that the vibration displacement exceeds the limit, an indicator lamp corresponding to limit exceeding of the vibration displacement turns to red representing alarming, and an audible alarm may be given (for example, continuous alarming sounds).
F: the intrinsic frequency, determined by fast Fourier transform, of the hoisting container is compared with the external excitation frequency, if the intrinsic frequency of the hoisting container is very approximate to the external excitation frequency, resonance may be triggered, and at this moment, an indicator lamp corresponding to resonance turns to red representing alarming, and an audible alarm may be given (for example, continuous alarming sounds).
For the embodiment including the second sensing unit 60 (for example, the double-hall sensor and the like), the pulse signals acquired by the second sensing unit 60 reach the data display and analysis processing platform 50 through the container top relay device 20, the wellhead receiving relay device 30 and the parsing gateway 40. Correspondingly, the data display and analysis processing platform 50 may specifically include: a pulse data receiving module, a descent depth calculation module and a depth display module. The pulse data receiving module is used for receiving parsed pulse data sent by the parsing gateway 40. The descent depth calculation module is used for calculating a descent depth of the hoisting container 1 according to the pulse data. The depth display module is used for displaying the descent depth of the hoisting container 1 in real time.
In addition, the data display and analysis processing platform 50 may further display a loading and unloading and hoisting simulation animation, for example, simulating coal loading, coal unloading and hoisting processes of the skip, and display a coal load in the skip and coal adhesion during unloading in the skip in real time. A relative position of the skip in an interface changes along with a change of a practical position of the skip in the well, and an in-place signal of the skip may further be indicated.
For the system embodiment including the explosion-proof and intrinsic safety type power box, the data display and analysis processing platform 50 may include: a power data receiving module and a power alarming module. The power data receiving module is used for receiving parsed power data sent by the parsing gateway 40. The power alarming module is used for judging whether power is insufficient or not according to a preset threshold value, and performs display and failure indication.
In each abovementioned system embodiment, the data display and analysis processing platform 50 may further store an alarming record and provide an alarming record query function.
On the basis of each embodiment of the online monitoring system for the suspension steel wire ropes of the hoisting container, the disclosure further provides an online monitoring method. FIG. 8 is a flowchart of an embodiment of an online monitoring method according to the disclosure. In the embodiment, the online monitoring method includes the following steps:
in Step 100, a first sensing unit 10 acquires a first state parameter capable of characterizing the suspension steel wire ropes 3 in real time, and transmits it to a container top relay device 20;
in Step 200, the container top relay device 20 receives the first state parameter acquired by the sensing unit, and transmits the first state parameter to a wellhead receiving relay device 30 by virtue of a frequency modulation spread spectrum and time division multiple wireless technology;
in Step 300, the wellhead receiving relay device 30 sends received data to a data display and analysis processing platform 50 via a parsing gateway 40 for data display, analysis and processing.
In the embodiment, the first state parameter may include oil pressure signals of balancing oil cylinders corresponding to each suspension steel wire rope 3 on a steel wire rope tension hydraulic automatic balancing device 2 arranged at a top of the hoisting container 1 respectively, and may further include transverse and longitudinal vibration signals of each suspension steel wire rope 3 on the steel wire rope tension hydraulic automatic balancing device 2 arranged at the top of the hoisting container 1 respectively.
FIG. 9 shows another embodiment of an online monitoring method according to the disclosure. Step 300 of the embodiment specifically includes the following steps compared with the abovementioned embodiment:
in Step 310, the wellhead receiving relay device 30 transmits the received data to the parsing gateway 40 in a frequency modulation communication manner;
in Step 320, the parsing gateway 40 parses the received data, and sends it to the data display and analysis processing platform 50.
In addition, for the embodiment of the online monitoring system including the second sensing unit 60 for the suspension steel wire ropes of the hoisting container, before Step 300, the method further includes the following steps:
in Step 600, the second sensing unit 60 acquires a second state parameter capable of characterizing rotation turns of a hoisting drum in real time, and transmits the second state parameter to the wellhead receiving relay device 30. The second state parameter may include pulse signals acquired and measured by two steel magnets of a double-hall sensor symmetrically arranged on two sides of a rotating shaft of the hoisting drum.
For different sensing data, the data display and analysis processing platform 50 may implement corresponding receiving and processing processes. FIG. 10 is a flowchart of receiving and processing oil pressure data in an embodiment of an online monitoring method according to the disclosure. For the oil pressure signals of the balancing oil cylinders, a receiving and processing process of the data display and analysis processing platform 50 includes the following steps:
in Step 411, the data display and analysis processing platform 50 receives parsed oil pressure data sent by the parsing gateway 40;
in Step 412, the data display and analysis processing platform 50 calculates tension values of the corresponding suspension steel wire ropes 3 according to the oil pressure data;
in Step 413, the data display and analysis processing platform 50 calculates a tension unbalance degree of the suspension steel wire ropes 3 according to the tension values, and judges whether the tension unbalance degree is smaller than the preset threshold values or not, a red lamp representing alarming is turned on if YES, otherwise a green lamp representing a normality is turned on;
in Step 414, the data display and analysis processing platform 50 judges whether hoisting loads of the suspension steel wire ropes 3 are subjected to impact loads or not according to the tension values, a red lamp representing impact load alarming is turned on if YES, otherwise a green lamp representing a normality is turned on;
in Step 415, the data display and analysis processing platform 50 judges whether the hoisting loads are higher than a preset threshold value or not according to the tension values, a red lamp representing overload alarming is turned on if YES, otherwise a green lamp representing a normality is turned on;
in Step 416, the data display and analysis processing platform 50 calculates oil pressure changes according to the oil pressure data, and judges whether the oil pressure changes are smaller than a preset threshold value or not, a red lamp representing cylinder sticking alarming is turned on if YES, otherwise a green lamp representing a normality is turned on.
FIG. 11 is a flowchart of receiving and processing pulse data in an embodiment of an online monitoring method according to the disclosure. For the pulse signals acquired by the double-hall sensor, the receiving and processing process of the data display and analysis processing platform 50 includes the following steps:
in Step 421, the data display and analysis processing platform 50 receives parsed pulse data sent by the parsing gateway 40;
in Step 422, the data display and analysis processing platform 50 calculates a descent depth of the hoisting container 1 according to the pulse data;
in Step 423, the data display and analysis processing platform 50 displays the descent depth of the hoisting container 1 in real time.
FIG. 12 is a flowchart of receiving and processing vibration data in an embodiment of an online monitoring method according to the disclosure. For the transverse and longitudinal vibration signals of the steel wire ropes, a receiving and processing process of the data display and analysis processing platform 50 includes the following steps:
in Step 431, the data display and analysis processing platform 50 receives parsed vibration data sent by the parsing gateway 40;
in Step 432, vibration displacement diagrams of the corresponding suspension steel wire ropes 3 are calculated according to the vibration data;
in Step 433, spectrograms are obtained by fast Fourier transform of the vibration displacement diagrams;
in Step 434, the data display and analysis processing platform 50 judges whether a vibration displacement exceeds a limit or not or whether an external excitation frequency is approximate to an intrinsic frequency of the hoisting container 1 or not according to a preset threshold value, a red lamp representing vibration alarming is turned on if YES, otherwise a green lamp representing a normality is turned on.
In addition, for the system embodiment including an explosion-proof and intrinsic safety type power box, the online monitoring method may further include that: the container top relay device 20 transmits a power parameter of the explosionproof and intrinsic safety type power box to the wellhead receiving relay device 30;
and the data display and analysis processing platform 50 receives parsed power data sent by the parsing gateway 40, judges whether power is insufficient or not according to a preset threshold value, and performs display and failure indication.
Finally, it should be noted that: the above embodiments are adopted to only describe the technical solutions of the disclosure but in no way to limit the disclosure.
Although the disclosure has been described with reference to the preferred embodiments in detail, those skilled in the art should know that modifications to the specific implementation modes of the disclosure or equivalent replacements to part of technical characteristics and the like may still be made without departing from the spirit of the technical solutions of the disclosure, and all of them shall fall within the scope of the claimed technical solutions of the disclosure.
Claims (15)
1. An online monitoring system for suspension steel wire ropes of a hoisting container, comprising:
a first sensing unit, used for acquiring a first state parameter capable of characterizing the suspension steel wire ropes in real time, and further comprising:
multiple oil pressure sensors, arranged on bypasses of balancing oil cylinders corresponding to each suspension steel wire rope on a steel wire rope tension hydraulic automatic balancing device at the top of the hoisting container respectively and used for acquiring oil pressure signals of the corresponding balancing oil cylinders; and multiple vibration sensors, arranged at transverse and longitudinal positions of each suspension steel wire rope on a steel wire rope tension hydraulic automatic balancing device at the top of the hoisting container respectively and used for acquiring transverse and longitudinal vibration signals of the corresponding suspension steel wire ropes;
a parsing gateway;
a data display and analysis processing platform for data display, analysis and processing;
a wellhead receiving relay device, arranged on an inner wall of a wellbore or at a wellhead, so as to be used for sending received data to the data display and analysis processing platform via the parsing gateway; and a container top relay device, arranged at a top of the hoisting container, and is electrically connected with the first sensing unit, so as to be used for receiving the first state parameter acquired by the first sensing unit and transmitting the first state parameter to the wellhead receiving relay device by virtue of a frequency-hopping spread spectrum and time division multiple wireless technology.
2. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 1, further comprising a second sensing unit arranged on or around a hoisting drum of the hoisting container, which is electrically connected with the wellhead receiving relay device and is used for acquiring a second state parameter capable of characterizing rotation turns of the hoisting drum and transmitting the second state parameter to the wellhead receiving relay device.
3. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 2, wherein the second sensing unit comprises a doublehall sensor, and two steel magnets of the double-hall sensor are symmetrically arranged on two sides of a rotating shaft of the hoisting drum, and are used for acquiring measured pulse signals.
4. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 1, wherein an explosion-proof and intrinsic safety type power box is further arranged at the top of the hoisting container, and is used for supplying power to the first sensing unit and the container top relay device; and the container top relay device is an intrinsic safety type acquisition and sending box, and the wellhead receiving relay device is an intrinsic safety type wireless receiving box.
5. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 1, wherein the data display and analysis processing platform comprises:
an oil pressure data receiving module, used for receiving parsed oil pressure data sent by the parsing gateway;
a tension value calculation module, used for calculating tension values of the corresponding suspension steel wire ropes according to the oil pressure data; and a first failure indication module, used for calculating a tension unbalance degree, impact loads, hoisting loads or oil pressure changes of the suspension steel wire ropes according to the oil pressure data and the tension values, and performing display and failure indication according to preset threshold values.
6. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 3, wherein the data display and analysis processing platform comprises:
a pulse data receiving module, used for receiving parsed pulse data sent by the parsing gateway;
a descent depth calculation module, used for calculating a descent depth of the hoisting container according to the pulse data; and a depth display module, used for displaying the descent depth of the hoisting container in real time.
7. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 1, wherein the data display and analysis processing platform comprises:
a vibration data receiving module, used for receiving parsed vibration data sent by the parsing gateway;
a spectrogram obtaining module, used for calculating vibration displacement diagrams of the corresponding suspension steel wire ropes according to the vibration data, and obtaining spectrograms by fast Fourier transform; and a second failure indication module, used for judging whether a vibration displacement exceeds a limit or not or whether an external excitation frequency is approximate to an intrinsic frequency of the hoisting container or not according to a preset threshold value, and performing display and failure indication.
8. The online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 4, wherein the container top relay device is further used for transmitting a power parameter of the explosion-proof and intrinsic safety type power box to the wellhead receiving relay device; and the data display and analysis processing platform comprises: a power data receiving module, used for receiving parsed power data sent by the parsing gateway, and a power alarming module, used for judging whether power is insufficient or not according to a preset threshold value, and performing display and failure indication.
9. An online monitoring method for the online monitoring system for the suspension steel wire ropes of the hoisting container according to claim 1, comprising:
acquiring, by a first sensing unit, a first state parameter capable of characterizing the suspension steel wire ropes in real time, and transmitting it to a container top relay device;
receiving, by the container top relay device, the first state parameter acquired by the sensing unit, and transmitting the first state parameter to a wellhead receiving relay device by virtue of a frequency-hopping spread spectrum and time division multiple wireless technology;
transmitting, by the wellhead receiving relay device, the received data to the parsing gateway in a frequency-hopping communication manner; and parsing, by the parsing gateway, the received data, and sending it to the data display and analysis processing platform.
10. The online monitoring method according to claim 9, wherein the online monitoring system for the suspension steel wire ropes of the hoisting container further comprises a second sensing unit arranged on or around a hoisting drum of the hoisting container and electrically connected with the wellhead receiving relay device, and before sending, by the wellhead receiving relay device, the received data to the data display and analysis processing platform via the parsing gateway, the online monitoring method further comprising:
acquiring, by the second sensing unit, a second state parameter capable of characterizing rotation turns of the hoisting drum in real time, and transmitting the second state parameter to the wellhead receiving relay device.
11. The online monitoring method according to claim 10, wherein the second state parameter comprises pulse signals acquired and measured by two steel magnets of a double-hall sensor symmetrically arranged on two sides of a rotating shaft of the hoisting drum.
12. The online monitoring method according to claim 9, after sending, by the wellhead receiving relay device, the received data to the data display and analysis processing platform via the parsing gateway, further comprising:
receiving, by the data display and analysis processing platform, parsed oil pressure data sent by the parsing gateway, and calculating tension values of the corresponding suspension steel wire ropes according to the oil pressure data; and calculating, by the data display and analysis processing platform, a tension unbalance degree, impact loads, hoisting loads or oil pressure changes of the suspension steel wire ropes according to the oil pressure data and the tension values, and performing display and failure indication according to preset threshold values.
13. The online monitoring method according to claim 11, after sending, by the wellhead receiving relay device, the received data to the data display and analysis processing platform via the parsing gateway, further comprising:
receiving, by the data display and analysis processing platform, parsed pulse data sent by the parsing gateway, and calculating a descent depth of the hoisting container according to the pulse data; and displaying, by the data display and analysis processing platform, the descent depth of the hoisting container in real time.
14. The online monitoring method according to claim 9, after sending, by the wellhead receiving relay device, the received data to the data display and analysis processing platform via the parsing gateway, further comprising:
receiving, by the data display and analysis processing platform, parsed vibration data sent by the parsing gateway, calculating vibration displacement diagrams of the corresponding suspension steel wire ropes according to the vibration data, and obtaining spectrograms by fast Fourier transform; and judging, by the data display and analysis processing platform, whether a vibration displacement exceeds a limit or not or whether an external excitation frequency is approximate to an intrinsic frequency of the hoisting container or not according to a preset threshold value, and performing display and failure indication.
15. The online monitoring method according to claim 9, wherein an explosion-proof and intrinsic safety type power box is further arranged at the top of the hoisting container, and is used for supplying power to the first sensing unit and the container top relay device, and the online monitoring method further comprises:
transmitting, by the container top relay device, a power parameter of the explosion-proof and intrinsic safety type power box to the wellhead receiving relay device; and receiving, by the data display and analysis processing platform, parsed power data sent by the parsing gateway, judging whether power is insufficient or not according to a preset threshold value, and performing display and failure indication.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/CN2017/074533 WO2018152721A1 (en) | 2017-02-23 | 2017-02-23 | On-line monitoring system and method for suspension steel wire rope for hoisting container |
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| AU2017400814A1 true AU2017400814A1 (en) | 2019-02-21 |
| AU2017400814B2 AU2017400814B2 (en) | 2020-02-06 |
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| AU (1) | AU2017400814B2 (en) |
| WO (1) | WO2018152721A1 (en) |
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| CN113051709A (en) * | 2021-02-04 | 2021-06-29 | 宁波思高信通科技有限公司 | Fault analysis and prediction method based on turnout health management |
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| US7093693B1 (en) * | 1999-06-10 | 2006-08-22 | Gazdzinski Robert F | Elevator access control system and method |
| US6601679B2 (en) * | 2001-09-05 | 2003-08-05 | Otis Elevator Company | Two-part wireless communications system for elevator hallway fixtures |
| CN103303755B (en) * | 2013-05-08 | 2016-01-20 | 中国恩菲工程技术有限公司 | Mine hoist and control method thereof |
| CN204873387U (en) * | 2015-08-25 | 2015-12-16 | 中南大学 | Monitoring devices based on mine hoisting system |
| CN105203200B (en) * | 2015-09-07 | 2018-10-02 | 河南科技大学 | Steel wire rope oscillation crosswise signal measurement apparatus, method and oscillation crosswise monitoring method |
| CN106865375A (en) * | 2017-02-23 | 2017-06-20 | 太原理工大学 | Hoisting container hanging steel rope on-line monitoring system and method |
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| CN113051709A (en) * | 2021-02-04 | 2021-06-29 | 宁波思高信通科技有限公司 | Fault analysis and prediction method based on turnout health management |
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| ZA201802205B (en) | 2019-01-30 |
| AU2017400814B2 (en) | 2020-02-06 |
| WO2018152721A1 (en) | 2018-08-30 |
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