CN102341338A - Wire rope life management device and method - Google Patents
Wire rope life management device and method Download PDFInfo
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- CN102341338A CN102341338A CN2010800106383A CN201080010638A CN102341338A CN 102341338 A CN102341338 A CN 102341338A CN 2010800106383 A CN2010800106383 A CN 2010800106383A CN 201080010638 A CN201080010638 A CN 201080010638A CN 102341338 A CN102341338 A CN 102341338A
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- 238000000034 method Methods 0.000 title claims description 7
- 238000012937 correction Methods 0.000 claims abstract description 17
- 229910000831 Steel Inorganic materials 0.000 claims description 170
- 239000010959 steel Substances 0.000 claims description 170
- 230000033228 biological regulation Effects 0.000 claims description 10
- 230000008569 process Effects 0.000 claims description 4
- 238000004364 calculation method Methods 0.000 claims description 2
- 230000035939 shock Effects 0.000 abstract 3
- 238000001514 detection method Methods 0.000 description 16
- 238000010276 construction Methods 0.000 description 9
- 206010011906 Death Diseases 0.000 description 8
- 238000012545 processing Methods 0.000 description 8
- 238000005452 bending Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000008676 import Effects 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 239000000725 suspension Substances 0.000 description 4
- 239000011162 core material Substances 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 230000001737 promoting effect Effects 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
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- 230000000630 rising effect Effects 0.000 description 1
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- 230000003068 static effect Effects 0.000 description 1
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- 230000001052 transient effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
- B66D1/00—Rope, cable, or chain winding mechanisms; Capstans
- B66D1/54—Safety gear
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- Mechanical Engineering (AREA)
- Control And Safety Of Cranes (AREA)
Abstract
A cargo is hoisted and lowered via a wire rope and a sheave over which the wire rope is looped by paying out the wire rope from a drum and rewinding the wire rope to the drum. On the basis of load data relating to the cargo, which is outputted from a load cell provided in the sheave, the presence or absence of an actual load of the cargo and a shock load exceeding the actual load by a predetermined amount is detected (step 33). When the presence of the shock load is detected, the value obtained by multiplying the life subtraction value when the presence of the shock load is not detected by a correction coefficient having a value exceeding 1 is subtracted from the estimated life (step 34), and the new estimated life (the remaining usable number of times) of the wire rope is displayed (step 35).
Description
Technical field
The present invention relates to rope service-life management devices and method.
Background technology
Quality descends steel rope along with use.Particularly; At the hoisting crane that is used for the heavier relatively goods of transportation (moving) (for example; Overhead crane, whipping crane, crane in bridge type, unloading machine, cable crane, cable car or tower crane) under the situation of steel rope of (it comprises jenny and derrick crane), must find out in earnest that the quality of steel rope descends.
The steel rope fatigue strength of the number of times that use is bent based on steel rope (it crosses the number of times of pulley) is predicted life-span of the conventional steel rope that is used for hoisting crane.Its reason is that under the situation of hoisting crane, they use pulley mostly, and in the position that steel rope is crossed these pulleys, the quality of steel rope descends very serious.The specification sheets of Japanese Patent No.2748836 has been described a kind of life predication apparatus; This device is divided into a plurality of unit areas with steel rope; And on the per unit region base, consider that steel rope comes design life (accumulated fatigue degree) in the bigger fact of quality decline at pulley position place.
Carrying out the actual place of using hoisting crane to carry out work, except that the number of times (it crosses the number of times of pulley) that steel rope is bent, also exist and the relevant factor of steel rope quality falling head.This factor is the temporary transient load (hereinafter referred to as " impact load ") that produces when using the crane goods.The size of impact load depends on hoisting crane machine operation person's operation skill.According to prior art the prediction of rope service-life is not exceeded the prediction of (it comprises quantity and diameter of pulley of pulley or the like) of the structure of using hoisting crane in essence, and it does not consider the influence of impact load for rope service-life.
Summary of the invention
The objective of the invention is through considering because the damage that impact load bears steel rope the life-span of coming to calculate exactly steel rope.
Rope service-life management devices according to the present invention comprises: the Life Calculation module; It is used for the life-span (operable residue degree) that according to the rules life estimation formula calculates the estimation of steel rope; Wherein, Said steel rope is used for hoisting crane, and wherein hoisting crane is through extracting steel rope out (pay out) and steel rope is recoiled on the said cylinder from cylinder, comes to mention, transport and put down goods subsequently via this steel rope and the pulley that is meshed with this steel rope; The load data load module, its be used to accept from said goods sling its put down subsequently during the input of load data of said goods, wherein, said load data is the load sensor output that provides from said pulley; The actual payload computing module, it is used for calculating the actual payload of said goods based on the load data from said load data load module input; The impact load sensing module, it is used for the load data imported based on from said load data load module, comes sensing whether to exist to surpass the impact load of the amount of said actual payload regulation; And life-span update module; It is used for having sensed under the situation that has said impact load at said impact load sensing module; Through from the life-span of said estimation, deducting the life-span that certain is worth the new estimation of calculating this steel rope, wherein said a certain value be through will not sensing ubiquity (prevail) when having said impact load life-span minimizing value with have coefficient of correction greater than unit value and multiply each other and obtain.
Rope service-life management process according to the present invention may further comprise the steps: life estimation formula according to the rules calculates the life-span of the estimation of steel rope; Wherein, Said steel rope is used for hoisting crane; Wherein hoisting crane is through extracting steel rope out and steel rope is recoiled on the said cylinder from cylinder, comes to mention, transport and put down goods subsequently via this steel rope and the pulley that is meshed with this steel rope; The input of acceptance load data of said goods during being lifted to it and putting down subsequently of said goods, wherein, said load data is the load sensor output that provides from said pulley; Based on the said load data of having imported, calculate the actual payload of said goods; Based on the said load data of having imported, come sensing whether to have impact load above the amount of said actual payload regulation; And sensing under the situation that has said impact load; Through from the life-span of said estimation, deducting the life-span that certain is worth the new estimation of calculating this steel rope, wherein said a certain value is through will not sensing ubiquitous life-span minimizing value when having said impact load and having coefficient of correction greater than unit value and multiply each other and obtain.
Life estimation formula according to the rules calculates the life-span of the estimation of steel rope.The invention enables when hoisting crane is actual when using the steel rope in the life-span with the estimation that is calculated; Determine thereafter the degree (and therefore, calculating the life-span of the new estimation of this steel rope) that (using after this hoisting crane comes shipping goods) rope service-life is shortened.
In the various life estimation formula that proposed up to now any one can be used as the life estimation formula of said regulation.For example, can the Niemann formula be used as said life estimation formula, estimate the life-span of steel rope.In fact, also can use other life estimation formula (Zhitkov&Posoekhov formula, E.L.Klein formula and V.Zignoli formula or the like).Various life estimation formula recited above is in " Wire Rope Handbook " (steel rope handbook editorial board; Nikkan Kogyo Shimbunsha, publish March 30 nineteen ninety-five, the 352-352 page or leaf) and " All About Wire Rope (Last Volume)-The Road to Safety " (association of industry and commerce of shell mound; The iron and steel manufacturing activates research association; The association of industry and commerce of shell mound publishes the 153-158 page or leaf July 25 nineteen ninety-five) in be described.
The input of acceptance load data of goods during being lifted to it and putting down subsequently of goods, this is the load sensor output that provides from pulley.This load data comprises the continuous load value (by the detected load value of load sensor) during from hoisting crane goods being lifted to transportation (moving) and its and putting down.Can depict along the sequential chart of the time of passage through this load data.
Based on load data from load sensor, the actual payload of the goods that obtains to promote.For example; Can the ubiquitous load of time point after the specific time section that begin from mentioning of goods to pass be used as actual payload; Perhaps through beginning from the time point that mentioning of goods begins to pass after the first specific time section; Load during till the time point subsequently after the passage second specific time section averages the value that is obtained, and uses as actual payload.
After mentioning goods, the load that surpasses actual payload just works to load sensor.After mentioning goods, the acting load of load sensor is just depended primarily on the operation of craneman to hoisting crane.The goods if the craneman slings is apace then compared with slinging at a slow speed of this goods, and the load that is applied will be bigger.
Based on said load data, come sensing whether to have load above the amount of actual payload regulation.For example, if in load data, occur to surpass 110% load of actual payload, then confirm to exist impact load.
Sensing under the situation that has impact load; Through from the life-span of top mentioned estimation, deducting the life-span that certain is worth the new estimation of calculating this steel rope, wherein said a certain value is through will not sensing ubiquitous life-span minimizing value when having impact load and having coefficient of correction greater than unit value and multiply each other and obtain.Take an example that does not sense ubiquitous life-span minimizing value when having impact load; Utilize the value that obtains in the following manner: will use life-span through mentioned upward Niemann formula, divided by through use life-span to the Niemann formula based on the estimation of the steel rope that value obtained of detected actual payload based on the estimation of the steel rope that value obtained of the maximum lift load of hoisting crane.
According to the present invention; There is impact load if in load data, sense, then from the life-span of top mentioned estimation, deducts the value that through will not have impact load time the ubiquitous life-span minimizing value and the coefficient of correction that has greater than unit value multiply each other and obtained.To the situation that has impact load with do not exist the situation of impact load to compare, therefore, can calculate short life.Can calculate the life-span of the new estimation of steel rope, it has considered the damage to steel rope that generation produced according to impact load.
The rope service-life management devices can have display unit, and said display unit is used to show the life-span of the new estimation of the steel rope that is calculated.Can confirm to be used to replace the time of the steel rope that is using intuitively.In addition, can calculate and show the life-span of the estimation of steel rope in real time, and notify to its operator or on-the-spot administrator.Can prevent unexpected rope fracture accident.
The rope service-life management devices preferably has impact load excess computing module, and said module is used to calculate the excess that surpasses actual payload relevant with impact load.The life-span update module is used certain value as said coefficient of correction, wherein, the excess that impact load excess computing module is calculated is big more, and the value of then using is just big more.Not only can perhaps not exist, can also be based on the size of impact load under the situation that has impact load, calculate the life-span of the new estimation of steel rope based on the existence of impact load.
Description of drawings
Fig. 1 shows the block diagram of the simplified structure of hoisting crane;
Fig. 2 shows from the figure of the load data of load sensor output;
Fig. 3 shows the transparent view of the outward appearance of rope service-life management devices;
Fig. 4 shows the block diagram of the electrical arrangement of rope service-life management devices;
Fig. 5 shows the example that screen is set;
Fig. 6 shows the example of operation screen;
Fig. 7 shows the example that data are set;
Fig. 8 shows the example that data are set; And
Fig. 9 shows the diagram of circuit of the flow process of the processing of being carried out by the rope service-life management devices.
The specific embodiment
Fig. 1 shows the simplified structure of mentioning, transporting and put down the hoisting crane of goods subsequently.(moving) mechanism (operation scheme) of advancing of this hoisting crane is not shown among Fig. 1.
Hoisting crane has steel rope 2 and has twined load drum 1 above that.The two ends of steel rope 2 all are fixed near the two ends of this load drum 1.When load drum 1 rotates forward, from load drum 1, extract steel rope 2 out.When load drum 1 contrarotation, steel rope 2 is recoiled on the load drum 1.The axle of load drum 1 is connected on lifting/recoil driving engine 2.Rotate this axle of driving through lifting/recoil driving engine 2, forward direction and rotary lifting cylinder 1 oppositely.The driving of lifting/recoil driving engine 2 (control of hand of rotation, rotation begin and stop control from reaching this rotative speed of control or the like) is realized by the craneman.
The a plurality of pulleys that below load drum 1, provide steel rope 2 to twine above that.In hoisting crane shown in Figure 1, placed equalizer pulley 3 in winding (loopback) position of steel rope 2.On each side of equalizer pulley 3, to have placed dead sheave 4 and two removable pulleys (lifting hook pulley) 5,6 around the mode of left and right symmetry of equalizer pulley 3.The suspension hook 7 of Suspended Cargo is connected to removable pulley 5,6.
Because steel rope 2 is extracted out from load drum 1 when load drum 1 forward direction rotates, so the removable pulley 5,6 that steel rope 2 twines above that moves down.Because steel rope 2 is wound on the load drum 1 when load drum 1 contrarotation, therefore removable pulley 5,6 moves up.Along with the rising of removable pulley 5,6 or descend, be suspended on goods on the suspension hook 7 and be raised or reduce.
To be used to detect the load sensor 8 that is applied to the load on the equalizer pulley 3 and be installed in equalizer pulley 3.Load sensor 8 can have desktop type, extruding type, tension force type, amplifier type, bearing type or follow closely type or the like.From load sensor 8 outputs and the corresponding voltage of load.The voltage of exporting from load sensor 8 is applied to rope service-life management devices 10.
Fig. 2 is to draw the time and along the form of the figure of plotted load (with this corresponding voltage of loading) along horizontal shaft; Show during being lifted to it and putting down subsequently of goods, from load sensor 8 data output and that be applied to rope service-life management devices 10.Details about term shown in this Fig will be described after a while.
As stated, hoisting crane will be suspended on goods on the suspension hook 7 and mention, moves and put down subsequently.After mentioning the goods that remains static, very big load just acts on equalizer pulley 3.Himself compare with goods, the load that after mentioning this goods, acts on equalizer pulley 3 is just bigger.Hereinafter will temporarily act on equalizer pulley 3 after mentioning goods bigger load is called " impact load ".The size of this impact load depends primarily on craneman's operation skill.
When mentioning goods, steel rope 2 is in its state of from load drum 1, having extracted out.Therefore, because impact load has very strong influence to steel rope 2.If impact load is bigger, then to compare with the less situation of impact load, its degree to the damage that steel rope 2 causes is bigger.Compare with the steel rope 2 that does not receive greater impact load continuously, fast more to the damage development ground of the steel rope 2 that receives the greater impact load continuously.
Rope service-life management devices 10 passes through not only to consider to use the number of times of steel rope 2, but also considers the influence of impact load, predicts the replacement time (calculating its life-span) of the steel rope 2 that is using in the hoisting crane.
Fig. 3 shows the transparent view of the outward appearance of rope service-life management devices 10, and Fig. 4 shows the block diagram of the electrical arrangement of rope service-life management devices 10.
The front elevation of rope service-life management devices 10 is provided, and is the display unit 12 with display panel that can videotex at it than top, is the input block 13 with the TIP that comprises numerical key than the lower part at it.Show that on the display panel of display unit 12 screen (being used to import the screen that data are set) is set shields (screen that is used to show the serviceability etc. of hoisting crane) with operating.
Fig. 5 shows the example that screen is set that on the display panel of display unit 12, shows, Fig. 6 shows the example of operation displayed screen on the display panel of display unit 12.Use the TIP of input block 13, carry out switching that is provided with between screen and the operation screen or the like.
With reference to Fig. 5, what on the display panel of display unit 12, shown is provided with on the screen title that shows a plurality of projects that will import (setting).Use input block 13 to import the character that perhaps is used to specify this digital value with the corresponding digital value of items displayed title.With reference to Fig. 6; Operating period of hoisting crane or after, attend display operation state on institute's operation displayed screen [number of times (remaining operable number of times) (description after a while) that the number of times that the actual payload of the goods of mentioning, steel rope have used (access times of accumulation) and residue are used or the like] at the display panel of display unit 12.
Once more with reference to Fig. 3 and Fig. 4, the input/output end port 14 (invisible Fig. 3) of the voltage that provides from aforesaid load sensor 8 to its input is provided on the back side of rope service-life management devices 10.The input/output end port 14 of load sensor 8 and rope service-life management devices 10 is electrically connected by signal wire (SW) (coaxial cable etc.).
Rope service-life management devices 10 comprises and is used for CPU 11 that the operation of rope service-life management devices 10 is managed as a whole.Above mentioned display unit 12, input block 13 and input/output end port 14 be connected to CPU 11.Be connected to the RAM 15 that also is useful on temporarily stored programme and data of CPU 11 and be used to store ROM 16 that data and program are set or the like.
Fig. 7 and Fig. 8 show to use the data that are provided with of shielding among the ROM 16 that imports and be stored in rope service-life management devices 10 are set.
This is provided with data and comprises the data relevant with hoisting crane and steel rope 2, and with the relevant data of evaluation criteria (for example, being used for confirming the standard of executed load/unload).The data that are provided with shown in Fig. 7 are be provided with data relevant with hoisting crane and steel rope 2.The data that are provided with shown in Fig. 8 are be provided with data relevant with evaluation criteria.
With reference to Fig. 7, comprise following data with hoisting crane and the steel rope 2 relevant data that are provided with:
Rope diameter d: it is the diameter of the steel rope 2 that uses in the hoisting crane.
Diameter of pulley D1: it is the diameter of the pulley that uses in the hoisting crane (above mentioned equalizer pulley 3, dead sheave 4 and removable pulley 5,6).
Diameter of cylinder D2: it is the diameter of load drum 1.
Cross-sectional area A: it is the effective cross section area of steel rope 2.
Workload W: it is the maxim (rated value) of the load of the steel rope 2 that is applied in fact to use in the hoisting crane.Under the situation of the hoisting crane shown in Fig. 1, because steel rope 2 is wrapped in the fact on equalizer pulley 3, dead sheave 4 and the removable pulley 5,6, so steel rope 2 has eight drop wires (fall) (load is treated to and is distributed among eight steel ropes 2).If the lifting load (rated load) of supposition hoisting crane is 40 tons, suppose that then the 40/8=5 ton is the workload W relevant with steel rope 2.
The quantity X that rope is sagging: the quantity of its steel rope that comes down to use in the hoisting crane 2, this quantity that is based on the pulley that hoisting crane has obtains, as stated.
Rope is crossed the frequency n of pulley (bending)
1: it is that the point (zone of regulation) on the steel rope 2 is crossed the number of times of pulley during the mentioning and put down (circulation) of goods.Under the situation of the hoisting crane shown in Fig. 1, on each side of equalizer pulley 3, arrange three pulleys (dead sheave 4 and two removable pulleys 5,6).Therefore, when promoting goods, steel rope 2 is crossed pulley three times, and steel rope 2 is crossed pulley three times (six times altogether) when putting down goods.Therefore, to cross the number of times of the pulley (bending) of the hoisting crane shown in Fig. 1 be six times to steel rope.
Steel rope is crossed the frequency n of cylinder (bending)
2: it is that the point (zone of regulation) on the steel rope 2 is crossed the number of times of load drum 1 during the mentioning and put down (circulation) of goods.Under the situation of the hoisting crane shown in Fig. 1, there is a load drum 1, therefore in a circulation, steel rope 2 is crossed this cylinder once.Therefore, to cross the number of times of the cylinder (bending) of the hoisting crane shown in Fig. 1 be once to steel rope.
The pulley coefficient
a: it is the value (coefficient) according to the flute profile of the pulley that uses in the hoisting crane (U-lag, V-shaped groove, undercut groove or the like) decision.The pulley coefficient
aBe used to through Niemann formula calculating steel rope 2 operable residue degrees (life-span of estimation) that use description after a while and the number of times (life-span minimizing value) that steel rope 2 has used.Usually, the pulley that has a U-lag generally is used for the pulley that hoisting crane uses.
Steel rope coefficient b: it is through using the Niemann formula to calculate the employed value of number of times (coefficient) that steel rope 2 operable residue degrees and steel rope 2 have used.Structure according to the steel rope 2 that uses is come regulation steel rope coefficient b (for example, this steel cord structure is " ordinary lay " or " afterturn in the same way ").
The correct-by-construction coefficient k
1, k
2, k
3: they are to be used for being similar to the mode of top mentioned rope coefficient b, proofread and correct the value (coefficient) of the number of times that steel rope 2 operable residue degrees and steel rope 2 used according to the structure of steel rope 2.The correct-by-construction coefficient k
1It is the value (coefficient) that meets the quantity of the rope of forming steel rope 2.The correct-by-construction coefficient k
2It is the value (coefficient) that meets the core material of steel rope 2 (steel core or fiber cores).The correct-by-construction coefficient k
3It is another value (coefficient) (shape of cross section [no matter cross-sectional plane is circle or non-circular (line of peculiar shape)] of forming the rope of steel rope 2 is no matter whether the surface of steel rope 2 is smeared or the like) that meets the structure of steel rope 2.
With reference to Fig. 8, the be provided with data relevant with evaluation criteria comprise following data:
Load detection load: it is the load of the lifting of goods (loading) that has been used for having confirmed the hoisting crane executed.If detect the load that is equal to, or greater than this loading detection load, then definite hoisting crane has been mentioned goods.
The unloading detection load: it is to be used to confirm that after hoisting crane was mentioned goods, this goods was put down the load of (unloading).If detect load, confirm that then this goods is put down less than this unloading detection load.
Load obtains time gap: the specified time section that the time of mentioned loading detection load begins above obtaining is that load obtains time gap, and is as shown in Figure 2.Be equal to, or greater than the load that loads detection load if detect; Detect load, in addition, comparing the longer time with load acquisition time gap less than the unloading detection load; Detect continuously and be equal to, or greater than the load that loads detection load and be equal to, or greater than the unloading detection load; Then definite hoisting crane has been carried out individual task, promptly by promoting, transport and put down subsequently the sequence of operations (circulation) (that is, having satisfied the loading and unloading standard) that goods constitutes.
Load reads type: use load in the average computation time gap to calculate the load (actual payload) of the goods that hoisting crane promotes.With reference to Fig. 2, the average computation time gap is from the acquisition time passage specific time that loads detection load (average delay time at interval) time of obtaining afterwards at interval, and obtains the period that time that time gap finishes finishes at load.Can select " instantaneous " perhaps " on average " read type as load.If selected " instantaneous ", time that then will be when the average computation time gap finishes (its with load obtain time that time gap finishes identical) detected load, the load (actual payload) of the goods of mentioning as hoisting crane is handled.If selected " on average ", the load (actual payload) of the goods that then will mention as hoisting crane at the aviation value of the load of the detection in the average computation time gap is handled.
Average delay time is at interval: as stated, it is from loading the acquisition time of detection load, and obtains the time gap (with reference to Fig. 2) that time that time gap finishes finishes at load.Above mentioned impact load (peak value) drop on average delay time at interval within.
End-of-life preparation warning condition: whether it is provided with and when the steel rope 2 operable residue degrees of predicting (residual life of estimation) reach certain percentum of new steel rope 2 operable residue degrees (initial lifetime), gives a warning.For example, 20% end-of-life preparation warning condition means, when the residual life of steel rope 2 reach initial lifetime 80% the time, give a warning.Can send this warning through warning tones or the demonstration that on display unit 12, appears with coming sense of hearing ground or vision.
Loading above normal capacity 1-3: when the actual payload of detected goods surpasses the lifting load (rated load) of hoisting crane, also can give a warning.Loading above normal capacity 1-3 is the load when sending this warning.Can send the warning relevant in a plurality of stages (rank) with loading above normal capacity.For example, be under 40 tons the situation,, then to give a warning at the lifting of hoisting crane load if the actual payload of detected goods is equal to, or greater than 45 tons.Through the actual payload according to detected goods be equal to, or greater than 45 tons and less than 50 tons, be equal to, or greater than 50 tons and less than 55 tons and be equal to, or greater than 55 tons various situation and change the demonstration on warning tones (perhaps volume) or the display unit 12; Which come to have used level other loading above normal capacity (that is the concrete load class of the goods of crane) to operator's untill further notice.
Coefficient of correction: its be used to proofread and correct according to above the value (coefficient) of size (that is, impact load surpasses the percentum of the actual payload of goods) number of times definition, that steel rope 2 has used of mentioned impact load.In this embodiment, be equal to, or greater than under 110% the situation of actual payload sensing impact load, carry out the processing of using this coefficient of correction to proofread and correct the number of times that uses steel rope.To describe after a while and use this coefficient of correction to proofread and correct the details of the processing of the number of times that uses steel rope.
Before being placed on steel rope 2 in the hoisting crane and hoisting crane operate; Relevant with hoisting crane and steel rope 2 data (Fig. 7) that are provided with that rope service-life management devices 10 uses storage among the ROM 16 are calculated steel rope 2 operable residue degrees (life-span of estimation) under the initial condition.
In this embodiment, described and used Niemann (G.Niemann) formula in known up to now a plurality of computing formula, calculated the operable residue degree of steel rope (life-span of estimation).Through the mode of example, at " Wire Rope Handbook " (steel rope handbook editorial board, Nikkan Kogyo Shimbunsha; Publish March 30 nineteen ninety-five; The 352-352 page or leaf) and " All About Wire Rope (Last Volume)-The Road to Safety " (association of industry and commerce of shell mound, the iron and steel manufacturing activates research association, association of industry and commerce of shell mound; Publish the 153-158 page or leaf July 25 nineteen ninety-five) in the details about the Niemann formula has been described.
The Niemann formula is suc as formula shown in (1).Based on the Niemann formula, calculate steel rope 2 and cross the times N of pulley up to its fracture
1(steel rope is by the number of times of pulley bending up to its fracture).
Here, a representes the pulley coefficient, and b is the steel rope coefficient, and D is a diameter of pulley, and d is a wirerope diameter, σ
tIt is the drawing stress (tensile stress) of steel rope.Try to achieve drawing stress σ through W/A
t(wherein, W is a workload, and A is the steel rope cross-sectional area).Calculating the times N that steel rope is crossed pulley
1The time digital value used formerly all be stored in (with reference to Fig. 7) among the ROM 16.
Next, calculating steel rope based on following formula (2) coefficient safe in utilization crosses pulley and bears the times N of 10% breakage up to it
2Should be noted in the discussion above that " 10% breakage " is the notion of using when considering safety.When steel rope ruptures fully, think that breakage is 100% breakage, and with " 10% breakage " be assumed to complete breakage 1/10 damage state based.
N
2=N
1* K
1Formula (2)
For example, with K
1=0.6 as safety K
1(1＞K
1).That is to say N
2＜N
1Set up.
Next, consider tired differential based on the steel rope formation, and based on following formula (3), utilization structure coefficient of correction K
2Proofreading and correct steel rope crosses pulley and suffers the times N of 10% breakage up to it
2
N
3=N
2* K
2Formula (3)
The correct-by-construction COEFFICIENT K
2It is the coefficient that rope structure determined according to the steel rope 2 that uses; It is scheduled in accordance with rope structure.With the correct-by-construction coefficient k that is stored in advance among the ROM 16
1, k
2, k
3(with reference to Fig. 7) is as the correct-by-construction COEFFICIENT K
2According to the structure of the steel rope 2 that uses, with the correct-by-construction coefficient k
1, k
2, k
3In any one or its combination (for example, value) through they are multiplied each other and obtained together as the correct-by-construction COEFFICIENT K
2Use.
The value N that is obtained based on top formula (3)
3Be called " limit number of bends ".
Remove this limit number of bends N through using to each hoisting crane circulation (mention, move and put down subsequently goods) steel rope 2 crooked number of times
3, calculate the cycle number used N about these pulleys
a(expression can repeat the on-cycle numerical value that how many times promotes, moves and put down subsequently goods).
Pulley can use cycle number: N
a=N
3/ n
1Formula (4)
Here, n
1The number of times of these pulleys is crossed in expression to each circulation steel rope 2.Use the numerical value of before having imported (setting), as shown in Figure 7 based on crane structure (quantity of pulley).
Also can use cycle number N to be similar to the cylinder that top described mode calculates about load drum 1
b(=N
3/ n
2).Its unique difference is: use diameter of cylinder (this value also is stored among the ROM 16 in advance) (Fig. 7) rather than suc as formula the diameter of pulley of the D in the Niemann formula of (1).Should be noted in the discussion above that n
2It is the number of times (Fig. 7) of crossing cylinder to each circulation steel rope 2.
Bending based on each place of supposition steel rope in these pulleys and cylinder is compound and fatigue accumulation, calculates this steel rope 2 operable residue degrees.According to following formula, pulley mentioned above the use can use cycle number N
aCan use cycle number N with cylinder
bCalculate steel rope 2 operable final residue degree N
x:
1/N
x＝(1/N
a)+(1/N
b)
N
x=1/ [(1/N
a)+(1/N
b)] formula (5)
The 2 operable residue degree N of steel rope under initial condition that calculate
x(that is initial lifetime) is stored among RAM 15 or the ROM 16.
As next will describe, according to the crane operation situation (the existence of considering aforesaid impact load or do not exist with and size after), reduce the 2 operable residue degree N of steel rope under initial condition that obtained
x, and calculate steel rope 2 operable new number of times (life-span of residual life, estimation).
Fig. 9 shows the diagram of circuit of flow process of the operation of rope service-life management devices 10.Figure with reference to the load data shown in Fig. 2 describes this diagram of circuit.
When manipulating crane, follow the voltage of the load of goods from load sensor 8 output, and it is offered rope service-life management devices 10.The load data (magnitude of voltage) (with reference to Fig. 2) that load sensor 8 is provided is stored among the RAM 15 of rope service-life management devices 10 (step 31).
At first, judge whether to satisfy load/unload standard (step 32).This is the purpose that is used for the life-span management of (operation cycle is to constitute by mentioning, moving and put down goods) execution steel rope 2 under the situation that hoisting crane is finished the work basically.
Use the normal data (data are set) shown in Fig. 8 to judge whether to satisfy the load/unload standard.With reference to Fig. 2; If detect the load that is equal to, or greater than said loading detection load, detect load, in addition less than said unloading detection load; Comparing the longer time with load acquisition time gap; Detect the load that is equal to, or greater than this loading detection load and is equal to, or greater than this unloading detection load continuously, then confirmed hoisting crane executed individual task, i.e. sequence of operations (circulation) (step 32 " being ").
For example, though even cause under the situation that suspension hook 7 waves in the influence owing to wind, load sensor 8 is output voltage also, in this case, does not satisfy the load/unload standard.If the load data from load sensor 8 does not satisfy the load/unload standard, then rope service-life management devices 10 is not carried out any specific processing (step 32 " denying ").
If load sensor 8 provides the load data that satisfies the load/unload standard, judge then whether the maxim (peak value) (impact load) that comprises in this load data surpasses 110% (step 33) of actual payload.As stated, read the type place at load and select under the situation of " instantaneous ", actual payload is the ubiquitous load that detects when the average computation time gap finishes.If selected " on average ", then actual payload is the aviation value of detected load during the average computation time gap.
If impact load is equal to or less than 110% of actual payload, think that then impact load does not influence (that is, not having impact load) (step 33 " denying ") to steel rope 2.
In this case, control advances to the general processing (being used to calculate the processing of operable residue degree) (step 35) that is used to deduct the number of times that this rope uses.
In the processing that is used for deducting the number of times that steel rope uses, calculate below carrying out (step 35):
At first,, use and calculate steel rope 2 operable residue degree N to (5) according to formula (1) based on the actual payload that load data obtained from load sensor 8
1Use workload W
(for example, having the structure shown in Fig. 1 if the lifting of hoisting crane load is 40 tons and this hoisting crane, then workload W=5 ton) (it is based on the drawing stress σ that uses in the supposition Niemann formula (with reference to Fig. 7)
tUnder the situation of (=W/A), lifting that hoisting crane can be sling load (rated load)), mentioned 2 operable residue degree N of steel rope under initial condition above calculating
xOn the other hand, exist with promoting load and compare, the load of the actual goods that promotes is the situation of light (perhaps heavier) more.For example, if 40 tons of hoisting cranes are handled 40 tons of goods, then this is the disposable use of supposition steel rope 2.But if handle compare lighter goods (for example, 30 tons) with 40 tons, then this is that supposition is compared use still less with the disposable use of steel rope 2.
According to following formula (6), calculate quantity (the life-span minimizing value) H of the use of steel rope 2
1
H
1=N
x/ N
1Formula (6)
According to following formula (7), calculate steel rope 2 operable new residue degree (life-span of residual life, estimation) H
Remain
H
Remain=N
x-H
1Formula (7)
The steel rope 2 operable residue degree H that calculated
RemainWith load (actual payload) that promotes and access times (as long as the basic work of hoisting crane execution up to now; Just calculate the accumulated value of the number of times that this steel rope uses) or the like, be presented at (step 36 on the display panel of display unit 12 of rope service-life management devices 10 together; With reference to Fig. 6).
On the other hand, if impact load surpasses 110% of actual payload, then steel rope 2 is treated to the damage (step 33 " being ") that receives the conflict load.
In this case, access times (the life-span minimizing value) H of use mentioned steel rope 2 above inciting somebody to action
1The value that multiplies each other and obtained with the coefficient of correction of the size that meets impact load (coefficient that surpasses unit value).
Be provided with the coefficient of correction of the size that meets impact load in advance, and it is stored among the ROM 16, as shown in Figure 8.For example, when impact load be actual payload 115% the time, with the access times H of steel rope
1Multiply by result treatment that coefficient 1.240 obtains access times H for this steel rope
1In the lifting capacity of considering instantaneous application and under the situation of the lifting capacity after removing impact load, use the Niemann formula to seek the coefficient of correction of the size that meets impact load.
Impact load is big more, and the value that then is used as coefficient of correction is with regard to bigger (with reference to Fig. 8).Therefore, impact load is big more, then the access times of this steel rope (life-span minimizing value) H
1The value that is appeared is just big more.
Be similar to top described calculating [formula (7)], through from the 2 operable residue degree N of steel rope under initial condition
xDeduct the access times H of this steel rope that is obtained
1, calculate the new residue degree H that steel rope 2 uses
Remain(step 34).With the steel rope of having considered impact load 2 operable residue degree H
RemainBe presented at (step 36) on the display panel.
Self-evident is to be used for from calculating steel rope 2 operable residue degree H for the second time
RemainProcessing in, from the steel rope 2 operable residue degree H that before calculated
RemainIn deduct the access times H of this steel rope that calculates
1
When calculating steel rope 2 operable residue degree H
RemainThe time, judge whether it has reached the access times (step 37) before end-of-life of setting.Based on the end-of-life preparation warning condition that is provided with in advance, come the access times (with reference to Fig. 8) before end-of-life of calculating and setting.(in fact, can calculate this value in advance, and subsequently it is stored among the ROM 16).For example, if end-of-life preparation warning condition is 20%, then 80% of steel rope 2 operable residue degrees value (that is, through multiply by 0.8 value that obtains) becomes the access times before end-of-life of said setting under initial condition.If the steel rope that calculates 2 operable residue degree H
RemainDrop to below the access times before the end-of-life of previous setting, then demonstration through appearing on warning tones or the display panel, (" being " of step 37 gives a warning; Step 38).
Claims (5)
1. rope service-life management devices comprises:
The Life Calculation module; It is used for the life-span that according to the rules life estimation formula calculates the estimation of steel rope; Wherein, Said steel rope is used for hoisting crane, and wherein hoisting crane is through extracting said steel rope out and said steel rope is recoiled on the said cylinder from cylinder, comes to mention, transport via said steel rope and the pulley that is meshed with said steel rope also to put down goods subsequently;
The load data load module, it is used to accept the input of the load data of said goods during being lifted to it and putting down subsequently of said goods, and wherein, said load data is the load sensor output that provides from said pulley;
The actual payload computing module, it is used for based on calculating the actual payload of said goods from the load data of said load data load module input;
The impact load sensing module, it is used for based on from the load data of said load data load module input, comes sensing whether to exist to surpass the impact load of the amount of said actual payload regulation; And
The life-span update module; It is used for having sensed under the situation that has said impact load at said impact load sensing module; Through from the life-span of said estimation, deducting the life-span that certain is worth the new estimation of calculating said steel rope, wherein said certain value is through will not sensing ubiquitous life-span minimizing value when having said impact load and having coefficient of correction greater than unit value and multiply each other and obtain.
2. rope service-life management devices according to claim 1 also comprises:
Impact load excess computing module, it is used to calculate excess relevant with said impact load, that surpass said actual payload;
Said life-span update module is used certain value as said coefficient of correction, wherein, the excess that is calculated by said impact load excess computing module is big more, and the said value of then using is just big more.
3. rope service-life management devices according to claim 1 and 2 also comprises:
Display unit is used to show life-span of the said new estimation of the said steel rope that is calculated by said life-span update module.
4. according to any described rope service-life management devices in the claim 1 to 3, wherein, the Niemann formula is as the life estimation formula of said regulation.
5. rope service-life management process may further comprise the steps:
Life estimation formula according to the rules calculates the life-span of the estimation of steel rope; Wherein, Said steel rope is used for hoisting crane; Wherein hoisting crane is through extracting said steel rope out and said steel rope is recoiled on the said cylinder from cylinder, comes to mention, transport via said steel rope and the pulley that is meshed with said steel rope also to put down goods subsequently;
The input of acceptance load data of said goods during being lifted to it and putting down subsequently of said goods, wherein, said load data is the load sensor output that provides from said pulley;
Based on the said load data of having imported, calculate the actual payload of said goods;
Based on the said load data of having imported, come sensing whether to have impact load above the amount of said actual payload regulation; And
There is said impact load if sense; Then through from the life-span of said estimation, deducting the life-span that certain is worth the new estimation of calculating said steel rope, wherein said certain value is through will not sensing ubiquitous life-span minimizing value when having said impact load and having coefficient of correction greater than unit value and multiply each other and obtain.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2009051807A JP5270404B2 (en) | 2009-03-05 | 2009-03-05 | Wire rope life management apparatus and method |
| JP2009-051807 | 2009-03-05 | ||
| PCT/JP2010/054167 WO2010101305A1 (en) | 2009-03-05 | 2010-03-05 | Wire rope life management device and method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN102341338A true CN102341338A (en) | 2012-02-01 |
| CN102341338B CN102341338B (en) | 2013-12-11 |
Family
ID=42709841
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2010800106383A Expired - Fee Related CN102341338B (en) | 2009-03-05 | 2010-03-05 | Wire rope life management device and method |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JP5270404B2 (en) |
| KR (1) | KR101321193B1 (en) |
| CN (1) | CN102341338B (en) |
| MY (1) | MY166567A (en) |
| SG (1) | SG174173A1 (en) |
| WO (1) | WO2010101305A1 (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103112781A (en) * | 2013-02-20 | 2013-05-22 | 大连博瑞重工有限公司 | Crane steel wire rope bending time recording and calculating method |
| CN104401874A (en) * | 2014-10-11 | 2015-03-11 | 太原科技大学 | Assessment method of whole-course real-time service life of lifting steel wire rope of crane |
| CN104822618A (en) * | 2013-03-29 | 2015-08-05 | 株式会社日立产机系统 | Hoist life calculating device |
| CN105725299A (en) * | 2016-04-01 | 2016-07-06 | 德清申力索具有限公司 | Safe garment |
| CN110894048A (en) * | 2018-09-12 | 2020-03-20 | 株式会社日立产机系统 | Wire rope monitoring device and wire rope monitoring method |
| CN115983838A (en) * | 2023-03-21 | 2023-04-18 | 江苏苏港智能装备产业创新中心有限公司 | Method, device and equipment for evaluating health of steel wire rope of crane hoisting mechanism and storage medium |
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| KR101225655B1 (en) * | 2010-11-23 | 2013-02-28 | 헤스본주식회사 | LIft for Vehicle |
| DE102013014265A1 (en) * | 2013-08-27 | 2015-03-05 | Liebherr-Components Biberach Gmbh | Device for detecting the Ablegereife a high-strength fiber rope when used on hoists |
| CN103935896B (en) * | 2014-03-28 | 2016-07-06 | 广西柳工机械股份有限公司 | Hoisting machinery steel wire rope multiplying power automatic identification equipment and recognition methods |
| CN109684784B (en) * | 2019-02-28 | 2022-06-07 | 攀钢集团攀枝花钢钒有限公司 | Method for monitoring service life of crane steel wire rope |
| KR102364170B1 (en) * | 2019-11-28 | 2022-02-18 | 한국조선해양 주식회사 | System for predicting life cycle of wire rope of goliath crane |
| KR102592161B1 (en) * | 2021-03-05 | 2023-10-19 | 오철규 | Intelligent safety mangement system for crane |
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| CN103112781B (en) * | 2013-02-20 | 2014-12-17 | 大连博瑞重工有限公司 | Crane steel wire rope bending time recording and calculating method |
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| CN104401874A (en) * | 2014-10-11 | 2015-03-11 | 太原科技大学 | Assessment method of whole-course real-time service life of lifting steel wire rope of crane |
| CN104401874B (en) * | 2014-10-11 | 2016-02-03 | 太原科技大学 | The appraisal procedure in crane hoisting wire rope omnidistance life-span in real time |
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| CN110894048A (en) * | 2018-09-12 | 2020-03-20 | 株式会社日立产机系统 | Wire rope monitoring device and wire rope monitoring method |
| CN115983838A (en) * | 2023-03-21 | 2023-04-18 | 江苏苏港智能装备产业创新中心有限公司 | Method, device and equipment for evaluating health of steel wire rope of crane hoisting mechanism and storage medium |
Also Published As
| Publication number | Publication date |
|---|---|
| CN102341338B (en) | 2013-12-11 |
| MY166567A (en) | 2018-07-17 |
| JP2010202377A (en) | 2010-09-16 |
| KR101321193B1 (en) | 2013-10-23 |
| WO2010101305A1 (en) | 2010-09-10 |
| KR20110133585A (en) | 2011-12-13 |
| SG174173A1 (en) | 2011-10-28 |
| JP5270404B2 (en) | 2013-08-21 |
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