CN101941649B - Automatic Detection and Fault Diagnosis Method of Crane Lifting State - Google Patents
Automatic Detection and Fault Diagnosis Method of Crane Lifting State Download PDFInfo
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Abstract
Description
技术领域 technical field
本发明涉及一种行车吊运状态自动检测及故障诊断方法,该方法能准确记录物料重量、行车吊运状态的变化,对称重传感器装置能进行有效的故障检测,为行车的全自动化作业创造条件。The invention relates to a method for automatic detection and fault diagnosis of the hoisting state of the crane. The method can accurately record the weight of materials and the change of the hoisting state of the truck, and can perform effective fault detection on the load cell device, creating conditions for the fully automatic operation of the truck. .
背景技术 Background technique
行车是物料库区执行生产物料运输及出入库任务的重要生产工具。现有的行车自动化程度较低,不能准确可靠的得到吊运物料的重量信息和吊运状态,已经成为了行车全自动化作业的一大技术瓶颈。The crane is an important production tool for the material storage area to perform the tasks of production material transportation and storage. The existing driving automation is relatively low, and the weight information and lifting status of the lifted materials cannot be obtained accurately and reliably, which has become a major technical bottleneck for the fully automated operation of the driving.
单一的称重传感器在复杂的工业环境下易损坏失效,抗干扰能力差,工作寿命短。一旦损坏就会使重量信息出错,从而给行车操作带来潜在危险。利用单一的电流传感器来检测重量,由于精度不够不能提供准确的重量信息。同时行车吊钩在吊运物料时往往有试吊或者调整吊钩位置的动作,此时都会产生传感器信号的抖动,单一的传感器对于这样的瞬时信号很难去判断是吊起还是放下动作。因此单一传感器方式的称重装置,由于其可靠性差,故障不易识别等原因不能提高库区管理的自动化程度。A single load cell is vulnerable to damage and failure in a complex industrial environment, with poor anti-interference ability and short working life. Once damaged, the weight information will be wrong, which will bring potential danger to driving operation. Using a single current sensor to detect weight cannot provide accurate weight information due to insufficient precision. At the same time, the driving hook often has the action of trial lifting or adjusting the position of the hook when lifting materials. At this time, the signal of the sensor will jitter. It is difficult for a single sensor to judge whether to lift or lower the action for such an instantaneous signal. Therefore, the weighing device in the form of a single sensor cannot improve the automation of warehouse management due to its poor reliability and difficult identification of faults.
行车主钩电机电流在吊起、放下物料时有明显不同的区间,根据这一个特性可以辅助判断吊起、放下操作。与称重传感器的配合使用还能增加冗余,对故障进行有效报警。The motor current of the main hook of the crane has obvious different intervals when lifting and lowering materials. According to this characteristic, it can assist in judging the lifting and lowering operations. The use in conjunction with the load cell can also increase redundancy and give an effective alarm to failures.
发明内容 Contents of the invention
技术问题:为了提高吊运状态信息识别的准确性,增加重量信息和吊运状态识别的可靠性和称重装置的可维护性。本发明提供一种行车吊运状态自动检测及故障诊断方法,在称重装置正常运行的情况下,不需人工干预就能自动判断物料重量信息和行车吊运状态,并且在称重或电流传感器有故障时及时报警。Technical problem: In order to improve the accuracy of hoisting status information identification, increase the reliability of weight information and hoisting status identification and the maintainability of weighing devices. The invention provides a method for automatic detection and fault diagnosis of the driving and lifting state. When the weighing device is in normal operation, the weight information of the material and the driving and lifting state can be automatically judged without manual intervention, and the weighing or current sensor Report to the police in time when there is a failure.
技术方案:本发明的行车吊运状态自动检测及故障诊断方法具体包括步骤如下:Technical solution: The automatic detection and fault diagnosis method of the driving and lifting state of the present invention specifically includes the following steps:
步骤一:在行车吊运状态自动检测系统离线状态下用不同标准重量物料进行吊起、放下操作,通过对称重传感器和电流传感器进行采集,得到多个物料重量Wk和对应的吊起电流Iuk、放下电流Idk或者稳定电流Isk,利用最小二乘法进行拟合得到物料重量与不同吊运状态下电流的重量-电流预估模型;Step 1: Under the off-line state of the automatic detection system of driving and lifting status, use materials of different standard weights to perform hoisting and lowering operations, and collect multiple material weights W k and corresponding lifting current I by collecting load cells and current sensors uk , put down the current I dk or stabilize the current I sk , use the least squares method to fit and obtain the weight-current estimation model of the material weight and the current under different lifting states;
步骤二:在线实际测量中对连续多次电流和重量信息用中位值平均滤波法进行滤波;Step 2: In the online actual measurement, filter the continuous current and weight information with the median value average filter method;
步骤三:通过对实际在线操作中,吊运某一物料时持续稳定电流和重量-电流预估模型下该重量下不同吊运状态电流区间的智能比较分析,准确的判断行车吊起、放下状态,并且在称重或电流传感器出故障时及时报错;Step 3: Through the intelligent comparison and analysis of the continuous stable current and the current range of different lifting states under the weight under the weight-current estimation model when lifting a certain material in the actual online operation, accurately judge the lifting and lowering state of the crane , and report an error in time when the weighing or current sensor fails;
步骤四:显示重量信息、吊运状态,或故障报警。Step 4: Display weight information, lifting status, or fault alarm.
所述的中位值平均滤波法对于连续采样的N个数据,去掉一个最大值和一个最小值,然后计算N-2个数据的算术平均值。The median average filtering method removes a maximum value and a minimum value for the N consecutively sampled data, and then calculates the arithmetic mean of the N-2 data.
所述的物料重量Wk和吊起电流Iuk通过最小二乘法拟合公式拟合得到I′uk=a0Wk+a1,其中a0和a1是拟合系数,拟合曲线与吊起电流Iuk的最大测量误差为Iλumax,可以预估出在物料重量Wk时,吊起电流模型区间为I′uk±Iλumax。The material weight W k and the hoisting current I uk are fitted by the least squares fitting formula to obtain I′ uk =a 0 W k +a 1 , wherein a 0 and a 1 are fitting coefficients, and the fitting curve is the same as The maximum measurement error of the hoisting current I uk is I λumax , and it can be estimated that when the weight of the material is W k , the hoisting current model range is I′ uk ±I λumax .
所述的物料重量Wk和放下电流Idk通过最小二乘法拟合公式拟合得到I′dk=a2Wk+a3,其中a2和a3是拟合系数,拟合曲线与放下电流Idk的最大测量误差为Iλdmax,可以预估出在物料重量Wk时,放下电流模型区间为I′dk±Iλdmax。Described material weight W k and putting down electric current I dk obtain I′dk =a 2 W k +a 3 by least square method fitting formula fitting, wherein a 2 and a 3 are fitting coefficients, fitting curve and putting down The maximum measurement error of the current I dk is I λdmax , and it can be estimated that when the weight of the material is W k , the range of the laying down current model is I′ dk ±I λdmax .
吊运某一物料时,当在垂直方向静止时,电流基本不变为Isk,进行多次测量后得到平均电流为I′sk,平均电流与垂直方向静止电流Isk的最大测量误差为Iλsmax,可以预估出垂直方向静止时,其电流区间为I′sk±Iλsmax。When lifting a certain material, when it is stationary in the vertical direction, the current basically does not change to I sk , and the average current is I′ sk after repeated measurements, and the maximum measurement error between the average current and the vertical static current I sk is I λsmax , it can be estimated that when the vertical direction is stationary, its current interval is I′ sk ±I λsmax .
所述在线实际测量过程中,得到物料重量信息W0和对应的电流信息I0,在拟合得到的重量-电流预估模型中将I0与模型中W0对应的电流区间进行比较,In the online actual measurement process, the material weight information W 0 and the corresponding current information I 0 are obtained, and in the weight-current estimation model obtained by fitting, I 0 is compared with the current interval corresponding to W 0 in the model,
如果I0∈I′sk±Iλsmax,则不作处理,等待下一次测量值,If I 0 ∈ I′ sk ±I λsmax , do not process and wait for the next measurement value,
如果I0∈I′dk±Iλdmax,则显示放下状态,If I 0 ∈ I′ dk ±I λdmax , then display the put down state,
如果I0落在吊起电流区间I′uk±Iλumax,则显示吊起状态,If I 0 falls within the hoisting current interval I′ uk ±I λumax , it will display the hoisting state,
如果I0都不在这两个区间,当I0更靠近I′dk,并且|I0-I′dk|/I′dk≤α,其中α根据工程实际确定,显示放下状态,同时记录该类情况次数,当达到一定次数时显示报警信息;否则当|I0-I′dk|/I′dk>α,显示称重或电流传感器故障需检修,If I 0 is not in these two intervals, when I 0 is closer to I′ dk , and |I 0 -I′ dk |/I′ dk ≤ α, where α is determined according to the actual project, display the state of release, and record the class at the same time The number of situations, when a certain number of times is reached, an alarm message will be displayed; otherwise, when |I 0 -I′ dk |/I′ dk >α, it will be displayed that the weighing or current sensor is faulty and needs to be repaired.
如果I0更靠近I′uk,并且|I0-I′uk|/I′uk≤α,显示放下状态,同时记录该类情况次数,当达到一定次数时显示报警信息;否则当|I0-I′uk|/I′uk>α,显示称重或电流传感器故障需检修,If I 0 is closer to I′ uk , and |I 0 -I′ uk |/I′ uk ≤ α, display the state of putting down, and record the number of times of this kind of situation at the same time, and display an alarm message when a certain number of times is reached; otherwise, when |I 0 -I′ uk |/I′ uk >α, indicating that the weighing or current sensor failure needs to be repaired,
从而自动判断是吊起/放下操作,并且在称重或电流传感器出故障时及时报错。Therefore, it is automatically judged that it is a lifting/lowering operation, and an error is reported in time when the weighing or current sensor fails.
有益效果:该方法采用称重传感器检测物料重量信息,电流传感器检测行车主钩电机电流信息。行车终端软件采集上述两种传感器获取的多组样本后,采用最小二乘法进行拟合得到重量-电流预估模型。在行车吊运过程中,对检测到的物料重量、对应主钩电流进行中位值平均滤波后,根据重量-电流预估模型进行智能分析,得到准确的行车吊运物料重量信息、吊运状态,并且在称重或电流传感器故障时及时报警,提高行车吊运状态监测的准确性和实时性,避免了吊钩试吊造成的误差。发明中涉及的自动识别技术能弥补人员操作库区的随机性、零乱性,为实现行车全自动作业提供技术基础。Beneficial effects: the method uses a weighing sensor to detect material weight information, and a current sensor to detect the current information of the driving main hook motor. After the driving terminal software collects multiple sets of samples obtained by the above two sensors, the least square method is used to fit the weight-current estimation model. During the crane lifting process, after performing median average filtering on the detected material weight and the corresponding main hook current, intelligent analysis is carried out according to the weight-current estimation model to obtain accurate driving material weight information and lifting status , and give an alarm in time when the weighing or current sensor fails, improving the accuracy and real-time monitoring of the crane's lifting status, and avoiding the error caused by the hook trial lifting. The automatic identification technology involved in the invention can make up for the randomness and disorder of personnel operating the storage area, and provide a technical basis for realizing fully automatic operation of driving.
附图说明 Description of drawings
下面结合附图和实施例对本实用新型进一步说明。Below in conjunction with accompanying drawing and embodiment the utility model is further described.
图1是本发明软件流程图。Fig. 1 is the software flowchart of the present invention.
图2是本发明所涉及行车俯视示意图。Fig. 2 is a schematic top view of the vehicle involved in the present invention.
图3是本发明所涉及重量-电流模型拟合算法流程图。Fig. 3 is a flow chart of the weight-current model fitting algorithm involved in the present invention.
图4是本发明所涉及智能分析子程序流程图。Fig. 4 is a flow chart of the intelligent analysis subroutine involved in the present invention.
图中有:行车大车1、行车小车2、行车工操作室3、行车吊钩4、称重传感器5、电流传感器6。In the figure, there are: driving cart 1,
具体实施方式Detailed ways
下面结合附图对本发明作进一步详细的说明。The present invention will be described in further detail below in conjunction with the accompanying drawings.
图1所示为本发明的数据流图,该方法采用称重传感器检测物料重量信息,电流传感器检测行车主钩电机电流信息。行车终端软件采集上述两种传感器获取的多组样本后,采用最小二乘法进行拟合得到重量-电流预估模型。在行车吊运过程中,对检测到的物料重量、对应主钩电流进行中位值平均滤波后,根据重量-电流预估模型进行智能分析,得到准确的行车吊运物料重量信息、吊运状态,并且在称重或电流传感器故障时及时报警。Fig. 1 shows the data flow chart of the present invention, the method adopts the weighing sensor to detect the material weight information, and the current sensor detects the current information of the driving main hook motor. After the driving terminal software collects multiple sets of samples obtained by the above two sensors, the least square method is used to fit the weight-current estimation model. During the crane lifting process, after performing median average filtering on the detected material weight and the corresponding main hook current, intelligent analysis is carried out according to the weight-current estimation model to obtain accurate driving material weight information and lifting status , and give an alarm in time when the weighing or current sensor fails.
本发明所涉及的行车结构如图2所示。物料库区行车主要由行车大车1、行车小车2、行车工操作室3、行车吊钩4等部分组成。称重传感器5安装在吊钩处,电流传感器6安装在行车主钩电机处,两个传感器数据与拟合得到的重量-电流预估模型进行比较得到行车吊起/放下动作。当行车吊运物料时,根据行车大车小车的位置信息和本发明确定的重量信息、行车状态信息就可以自动确定行车的操作,从而为行车的全自动作业提供技术基础。The driving structure involved in the present invention is shown in FIG. 2 . The driving in the material storage area is mainly composed of a driving cart 1, a
图3所示为本发明重量-电流拟合流程图,通过多次采样得到物料重量和对应电流。利用拟合公式(1)和(2)得到重量-电流预估模型I′xk=a0W′k+a1。对于不同的k,计算出最大测量误差ΔIxk=Ixk-I′xk,比较得出|ΔIxk|中最大值记为Ixλmax,其中x为u时表示吊起电流最大测量误差,当x为d时表示放下电流最大测量误差。因此对于不同物料重量Wk,其电流可以预估为I′xk±Ixλmax。具体到吊起电流表示为I′uk±Iλumax,放下电流为I′dk±Iλdmax,垂直方向静止电流为I′sk±Iλsmax。Fig. 3 shows the weight-current fitting flow chart of the present invention, in which the material weight and corresponding current are obtained through multiple sampling. The weight-current estimation model I′ xk =a 0 W′ k +a 1 is obtained by using fitting formulas (1) and (2). For different k, calculate the maximum measurement error ΔI xk =I xk -I′ xk , compare the maximum value in |ΔI xk | and record it as I xλmax , where x represents the maximum measurement error of the lifting current when x is u When it is d, it means the maximum measurement error of the current. Therefore, for different material weights W k , the current can be estimated as I′ xk ±I xλmax . Specifically, the hoisting current is expressed as I′ uk ±I λumax , the lowering current is I′ dk ±I λdmax , and the static current in the vertical direction is I′ sk ±I λsmax .
其中公式(1)、(2)中N表示采样次数,k表示第几次采样,Ixk的x为u时表示吊起电流,x为d时表示放下电流,x为s时表示垂直方向静止电流。Among them, N in the formulas (1) and (2) represents the number of sampling times, k represents the number of sampling times, when x of I xk is u, it represents the lifting current, when x is d, it represents the lowering current, and when x is s, it represents the vertical direction static current.
图4所示为本发明智能比较分析图。通过对传感器数据的定时采样得到物料重量W0和对应的状态电流I0,当进行一次采样后计数器1加一记录总采样次数。Fig. 4 shows that the intelligent comparative analysis diagram of the present invention. The material weight W 0 and the corresponding state current I 0 are obtained by timing sampling of the sensor data, and the counter 1 is incremented by one to record the total sampling times after a sampling.
如果I0∈I′sk±Iλsmax,则不作处理,等待下一次测量值。If I 0 ∈ I′ sk ±I λsmax , do not process and wait for the next measured value.
如果I0∈I′dk±Iλdmax,则显示放下状态。If I 0 ∈I′ dk ±I λdmax , the put down state is displayed.
如果I0落在吊起电流区间I′uk±Iλumax,则显示吊起状态。If I 0 falls within the hoisting current interval I′ uk ±I λumax , the hoisting state is displayed.
如果I0都不在这两个区间,当I0更靠近I′dk,并且|I0-I′dk|/I′dk≤α,其中α根据工程实际确定。显示放下状态,同时计数器2加一记录该类情况次数,当计数器2/计数器1>m(其中m的取值根据实际工程需要选取),显示报警信息;否则当|I0-I′dk|/I′dk>α,显示称重或电流传感器故障需检修。If I 0 is not in these two intervals, when I 0 is closer to I′ dk , and |I 0 -I′ dk |/I′ dk ≤α, where α is determined according to engineering practice. Display the state of putting down, and add one to the
如果I0更靠近I′uk,并且|I0-I′uk|/I′uk≤α,显示放下状态,同时计数器2加一记录该类情况次数,当计数器2/计数器1>m(其中m的取值根据实际工程需要选取),显示报警信息;否则当|I0-I′uk|/I′uk>α,显示称重或电流传感器故障需检修。If I 0 is closer to I' uk , and |I 0 -I' uk |/I' uk ≤ α, display the state of putting down, and add one to counter 2 to record the number of times of this type of situation, when
从而自动判断是吊起/放下操作,并且在称重或电流传感器出故障时及时报错。Therefore, it is automatically judged that it is a lifting/lowering operation, and an error is reported in time when the weighing or current sensor fails.
现结合实际,对图4进行进一步描述。实际起吊20吨物料时,主钩电流传感器每隔0.5秒得到6个不同的值为15.10mA,14.40mA,14.38mA,14.42mA,14.43mA,14.34mA。根据中位值平均滤波去掉15.10mA和14.34mA,得到平均值14.41mA,有效的滤去了偶然的脉冲电流,减弱了试吊等动作的影响。重量-电流预估模型中20吨对应的吊起电流为14.40±0.06mA,放下电流为13.23±0.06mA。通过比较发现实际测量电流14.41mA在模型中吊起电流区间,则显示吊起动作。若实际测量电流为13.31mA,则其不在起吊起电流和放下电流区间,进一步判断知道其更靠近吊起电流,并且与吊起电流的误差少于10%,则显示为吊起操作,并且让计数器2加一。当计数器2除以计数器1(总测量次数)的值大于m时,就显示称重或电流传感器有故障。若实际测量电流为11.38mA,则其不在起吊电流和放下电流区间,进一步判断知道其更靠近放下电流,并且与模型中放下电流的误差大于10%,则进行报警提示称重或电流传感器有故障。Combining with the actual situation, Fig. 4 will be further described. When actually lifting 20 tons of material, the main hook current sensor gets 6 different values of 15.10mA, 14.40mA, 14.38mA, 14.42mA, 14.43mA, 14.34mA every 0.5 seconds. Remove 15.10mA and 14.34mA according to the average filter of the median value, and get the average value of 14.41mA, which effectively filters out the occasional pulse current and weakens the influence of actions such as trial hanging. In the weight-current estimation model, the lifting current corresponding to 20 tons is 14.40±0.06mA, and the lowering current is 13.23±0.06mA. By comparison, it is found that the actual measured current 14.41mA is in the lifting current range in the model, and the lifting action is displayed. If the actual measured current is 13.31mA, it is not in the interval between the lifting current and the lowering current. Further judgment knows that it is closer to the lifting current, and the error with the lifting current is less than 10%, it is displayed as a lifting operation, and let
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CN102589681A (en) * | 2012-04-05 | 2012-07-18 | 邓昌建 | High-reliability wireless vibration measurement method and device for monitoring state of rotating equipment |
CN102879709A (en) * | 2012-07-17 | 2013-01-16 | 武汉朗德电气有限公司 | Real-time fault detection method for grounding circulation of feeder cable |
CN104111272A (en) * | 2014-08-04 | 2014-10-22 | 山东省计算中心(国家超级计算济南中心) | Error processing method for building enclosure structure thermal flux density collection system |
KR20160020002A (en) * | 2014-08-12 | 2016-02-23 | 주식회사 대산이노텍 | Apparatus for detecting hoist operating state |
US10634379B2 (en) * | 2017-09-28 | 2020-04-28 | Honeywell International Inc. | Actuators with condition tracking |
CN110642140B (en) * | 2018-06-27 | 2021-03-09 | 上海梅山钢铁股份有限公司 | Ladle hanging identification method for foundry crane |
CN111320082A (en) * | 2019-01-17 | 2020-06-23 | 上海欧冶物流股份有限公司 | Method and device for determining weight of goods and warehouse management method |
CN109573839B (en) * | 2019-01-17 | 2020-10-27 | 上海欧冶物流股份有限公司 | Warehouse cargo monitoring method and device |
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CN1537802A (en) * | 2003-04-17 | 2004-10-20 | 上海宝山十三冶金建设有限公司 | Multiangle distance limiter of crane |
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