CN103149042A - Safety evaluation decision making system of construction crane and safety evaluation decision making method thereof - Google Patents

Safety evaluation decision making system of construction crane and safety evaluation decision making method thereof Download PDF

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CN103149042A
CN103149042A CN2013100365006A CN201310036500A CN103149042A CN 103149042 A CN103149042 A CN 103149042A CN 2013100365006 A CN2013100365006 A CN 2013100365006A CN 201310036500 A CN201310036500 A CN 201310036500A CN 103149042 A CN103149042 A CN 103149042A
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crane
module
jib
control module
stress
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CN103149042B (en
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王欣
蔡福海
宋晓光
杨绍伟
黄一
潘志毅
黄燕
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CHANGZHOU YILIYA HEAVY INDUSTRY MACHINERY TECHNOLOGY Co Ltd
XUZHOU YILIYA ENGINEERING MACHINERY Co Ltd
DALIAN UNIVERSITY OF Technology (XUZHOU)ENGINEERING MACHINERY RESEARCH CENTRAL
Dalian University of Technology
Dalian Yiliya Construction Machinery Co Ltd
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CHANGZHOU YILIYA HEAVY INDUSTRY MACHINERY TECHNOLOGY Co Ltd
XUZHOU YILIYA ENGINEERING MACHINERY Co Ltd
DALIAN UNIVERSITY OF Technology (XUZHOU)ENGINEERING MACHINERY RESEARCH CENTRAL
Dalian University of Technology
Dalian Yiliya Construction Machinery Co Ltd
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Abstract

The invention discloses a safety evaluation decision making system of a construction crane, and a safety evaluation decision making method thereof. The safety evaluation decision making system of the construction crane comprises an external data detection module, a data acquisition module, a control module, a display input module, an interface module and a storage module, wherein the external data detection module is installed on the construction crane; the external data detection module is connected with the data acquisition module through analog quantity data signals in a communication mode; the data acquisition module is connected with the control module through the Ethernet in a communication mode; and the display input module, the interface module and the storage module are all electrically connected with the control module. According to the safety evaluation decision making system and the safety evaluation decision malign method, through data collected through the external data detection module, combination of a mechanical model of the construction crane, and a load-stress reflection relationship, determined key structural point stress in advance is calculated and recorded, cost is low, and real-time analysis of data and an early-warning function of the construction crane are achieved.

Description

The safety assessment decision system of crane and safety assessment decision-making technique thereof
Technical field
The present invention relates to safety assessment decision system and the safety assessment decision-making technique thereof of crane.
Background technology
Crane comprises polytype crane, comprise the polytypes such as truck-mounted crane, crawler crane, wheel-mounted crane, tower crane, lorry-mounted crane, its outstanding feature has two, one is maneuverability and the movability of height, another is to have one or more jib operating systems, completes lifting and operation to load.Crane is widely used in development of the national economy process, long term due to load, main load bearing component boom system, the turntable of crane, the main structural member such as get off can produce certain damage and fatigure failure may occur, the reason of this generation is that the original weld defects due to structural member itself enlarges and causes losing efficacy on the one hand, may be to lose efficacy because the various uncertain factors in use procedure cause material or parts overload on the other hand.In case main components such as the boom system of crane lost efficacy, might produce serious accident, therefore, record for the load of crane and the assessment of carrying out fatigue lifetime according to load has important practical value and economic implications to the safe handling of crane.
At present, what adopt for the load of crane record and residual life evaluation prediction is all separating apparatus, and namely the load record adopts a cover hardware detection device, and what adopt is all that interim foil gauge mount technology detects, ageing very poor.What the Fatigue Life Assessment prediction was adopted is that independent computing machine calculates, can't be in real time to data analysis and the early warning of crane, and precision of prediction is low, is difficult to effective real-time early warning, the impact evaluation precision.
Summary of the invention
First technical matters to be solved by this invention is to provide a kind of can the structure residual life of crane calculating, and automatically provides the safety assessment decision system of safety assessment conclusion and repair and maintenance suggestion.
In order to solve the problems of the technologies described above, technical scheme provided by the present invention is: the safety assessment decision system of crane comprises external data detection module, data acquisition module, control module, demonstration load module, interface module and memory module; Described external data detection module is arranged on crane; Connect by the analog data signal and communication between described external data detection module and data acquisition module; Be connected by ethernet communication between described data acquisition module and control module; Described demonstration load module, interface module and memory module all are electrically connected to control module.
Described external data detection module comprises the luffing pulling force sensor for the luffing pulling force information of gathering project crane, the jib angular transducer that is used for the jib angle information of gathering project crane, and the jib linear transducer that is used for the jib length information of gathering project crane.
The measurement range of the jib angular transducer of described external data detection module is 0 ° to 180 °.
Store the mechanical model database of the crane of various models in described memory module.
Second technical matters to be solved by this invention is to provide the safety assessment decision-making technique of the safety assessment decision system of crane.
In order to solve the problems of the technologies described above, technical scheme provided by the present invention is: the safety assessment decision-making technique of the safety assessment decision system of crane comprises the following steps:
1. luffing pulling force sensor, jib angular transducer, jib linear transducer are sent to control module with luffing pulling force information, jib angle information and the jib length information of crane respectively by data acquisition module;
2. the testing staff manually inputs the crane model to control module by the demonstration load module;
3. control module is called the stress model of the crane of this model according to the model of crane from the mechanical model database, simultaneously according to luffing pulling force information, jib angle information and jib length information, by load-stress mapping relations, calculate and record pre-determined key structure point stress;
4. control module by data recording, calculates the loading spectrum data of crane in a period of time;
5. the testing staff is according to the designing requirement of crane, and each key position of crane is carried out the emphasis monitoring, characterizes the safety index of whole crane with the force analysis of each key position of crane;
6. control module is calculated respectively the position that the crane needs carry out Fatigue Life Assessment according to four kinds of estimating method for fatigue life; Described four kinds of estimating method for fatigue life are respectively nominal stress method based on fuzzy damage, Local Stress-Strain Method, based on the fracture mechanics method of finite element and the computing method that merge based on aforementioned three kinds of methods;
7. four kinds of methods calculate complete after, adopt corresponding Fatigue Summation Damage Theory that damage is accumulated, and finally calculate the fatigue lifetime that crane needs assessment site;
8. control module according to cycle index and the load record of the requirement of crane design specifications, is calculated In-Service Engineering crane safe operation grade, and is provided suitable maintaining suggestion and safety assessment conclusion; Described assessment result comprises scrapping to be processed or demotes and use or keep in repair to use or continue and use safely.
After having adopted technique scheme, the present invention has following beneficial effect: (1) the present invention installs the external data detection module on crane, by the data of external data detection module collection and the stress model of incorporation engineering crane, and load-stress mapping relations, calculate and record pre-determined key structure point stress, cost is low, has realized real-time analysis and warning function to the crane data.
(2) store the mechanical model database of the crane of various models in memory module of the present invention, the direct stress that has greatly reduced the crane region of interest detects, by the calling data storehouse, can be by hoisting or variable amplitude loading, directly calculate the load data at each position, simplified general stress acquisition channel.
(3) the invention provides four kinds of estimating method for fatigue life, can select different computing method to be analyzed according to different cranes and different working conditions, increase the reliability of assessment result.
(4) the present invention's multiple interfaces that can provide by interface module with carry out the data communication after the former control system of crane, notebook computer, crack detection instrument, structural stress detecting instrument are connected, the partial parameters of correction model, thus the life appraisal precision of prediction improved.
Description of drawings
Content of the present invention is easier to be expressly understood in order to make, and the below is according to specific embodiment and by reference to the accompanying drawings, and the present invention is further detailed explanation, wherein
Fig. 1 is the structured flowchart of the safety assessment decision system of crane of the present invention.
Label in accompanying drawing is:
External data detection module 1, luffing pulling force sensor 11, jib angular transducer 12, jib linear transducer 13, data acquisition module 2, control module 3, demonstration load module 4, interface module 5, memory module 6.
Embodiment
(embodiment 1)
See Fig. 1, the safety assessment decision system of the crane of the present embodiment comprises external data detection module 1, data acquisition module 2, control module 3, shows load module 4, interface module 5 and memory module 6.
External data detection module 1 is arranged on crane.External data detection module 1 comprises the luffing pulling force sensor 11 for the luffing pulling force information of gathering project crane, the jib angular transducer 12 that is used for the jib angle information of gathering project crane, and the jib linear transducer 13 that is used for the jib length information of gathering project crane.The measurement range of jib angular transducer 12 is 0 ° to 180 °.Jib linear transducer 13 measurement ranges can be determined according to actual crane arm support length.Connect by the analog data signal and communication between external data detection module 1 and data acquisition module 2.Be connected by ethernet communication between data acquisition module 2 and control module 3.Show that load module 4, interface module 5 and memory module 6 all are electrically connected to control module 3.Store the mechanical model database of the crane of various models in memory module 6.
The multiple interfaces that the safety assessment decision system of this crane can provide by interface module 5 with carry out the data communication after the former control system of crane, notebook computer, crack detection instrument, structural stress detecting instrument are connected, the partial parameters of correction model, thus the life appraisal precision of prediction improved.
The computing method of the safety assessment decision system of crane comprise the following steps:
1. luffing pulling force sensor 11, jib angular transducer 12 and jib linear transducer 13 are sent to control module 3 with luffing pulling force information, jib angle information, the jib length information of crane respectively by data acquisition module 2;
2. the testing staff is by showing that the artificial input crane of load module 4 model is to control module 3;
3. control module 3 is called the stress model of the crane of this model according to the model of crane from the mechanical model database, simultaneously according to luffing pulling force information, jib angle information and jib length information, by load-stress mapping relations, calculate and record pre-determined key structure point stress;
4. control module 3 by data recording, calculates the loading spectrum data of crane in a period of time;
5. the testing staff is according to the designing requirement of crane, and each key position of crane is carried out the emphasis monitoring, characterizes the safety index of whole crane with the force analysis of each key position of crane;
6. control module 3 is calculated respectively the position that the crane needs carry out Fatigue Life Assessment according to four kinds of estimating method for fatigue life; Described four kinds of estimating method for fatigue life are respectively nominal stress method based on fuzzy damage, Local Stress-Strain Method, based on the fracture mechanics method of finite element and the computing method that merge based on aforementioned three kinds of methods;
7. four kinds of methods calculate complete after, adopt corresponding Fatigue Summation Damage Theory that damage is accumulated, and finally calculate the fatigue lifetime that crane needs assessment site;
8. control module 3 according to cycle index and the load record of the requirement of crane design specifications, is calculated In-Service Engineering crane safe operation grade, and is provided suitable maintaining suggestion and safety assessment conclusion; Described assessment result comprises scrapping to be processed or demotes and use or keep in repair to use or continue and use safely.
Nominal stress method based on fuzzy damage is to obtain the nominal stress spectrum of structure dangerous position according to the structural member loading spectrum, the method of using corresponding S-N curve and Cumulative Fatigue Damage rule computation structure fatigue lifetime, introduced the concept of degree of membership in the weight function of injury tolerance, and determine membership function according to different load situation, thereby calculate fuzzy impairment value, and according to Critical Damage value and the final assumed (specified) load spectrum of accumulated damage cycle period.
Its basic calculating formula is: λ = D CR ΣD ( S i ) = D CR ( Σ i = 1 m μ ( S i ) × n i N 0 + Σ i = m + 1 n μ ( S i ) × n i N i ) 。
In formula, λ is the loading spectrum cycle period.
D CRBe Critical Damage,
Figure BDA0000279548012
, D wherein maxBe maximum impairment value, desirable 1.1, Be the subordinate function of fatigue damage, be the function of θ.
The value of θ is as follows: θ 〉=0.33 o'clock, and μ (S) chooses the higher Γ of subjection degree and distributes; When θ＜0.33, μ (S) gets the less parabolic distribution of subjection degree; θ=/c 2For to the influential loading conditions of fatigue; c 3, c 2, c 1Be frequency corresponding to stress.
∑ D (S i) damage the accumulating injuring value that calculates after ambiguity, D (S for considering near fatigue limit i) computing formula be: D ( S i ) = μ ( S i ) × n i N 0 , S ≤ S f μ ( S i ) × n i N i , S > S f , μ (S wherein i) be the subordinate function of fatigue damage, n iFor becoming 10 according to each stress level by frequency expansion 6The effect number of times that obtains, N 0Corresponding fatigue lifetime during for fatigue limit, N iBe permanent width stress S iFatigue lifetime under effect, S iBe each rank stress, S fFatigue limit for member.
Local Stress-Strain Method is a kind of fatigue life evaluation method that grows up on breach strain analysis and low-cycle fatigue basis, is specially adapted to low-cycle fatigue.
Its basic calculating formula is:
During loading: ( σ - σ r ) 2 E + 2 ( σ - σ r ) ( σ - σ r 2 K ′ ) 1 n ′ = K f 2 C 2 Δ P 2 E ；
During unloading: ( σ r - σ ) 2 E + 2 ( σ r - σ ) ( σ r - σ 2 K ′ ) 1 n ′ = K f 2 C 2 Δ P 2 E 。
σ wherein rBe front once reverse local stress at the end; σ is this reverse local stress at the end; E is elastic modulus; K ' is the intensity of circulation coefficient; N ' is cyclic strain hardening exponent; K fBe fatigue notch factor; C is scale-up factor; Δ P is the load change scope.
Basic calculating formula based on the fracture mechanics method of finite element is:
When α is relevant with crack length: N = ∫ a 0 a c da C ( ΔK ) m = ∫ a 0 a c da C ( ασ πa ) m ?；
When α is constant: N = a c ( 1 - m 2 ) - a 0 ( 1 - m 2 ) ( 1 - m 2 ) C π m 2 α m ( Δσ ) m ?。
Wherein m, C are material constant; a 0Be the member initial crack; a cBe critical crack.
Figure BDA0000279548019
, K wherein ICBe the plane strain fracture toughness parameter.
Figure BDA00002795480110
, α is the form factor coefficient; σ is actual stress; A is crack length; K is stress intensity factor.
Above-described specific embodiment; purpose of the present invention, technical scheme and beneficial effect are further described; institute is understood that; the above is only specific embodiments of the invention; be not limited to the present invention; within the spirit and principles in the present invention all, any modification of making, be equal to replacement, improvement etc., within all should being included in protection scope of the present invention.

Claims (5)

1. the safety assessment decision system of crane, is characterized in that: comprise external data detection module (1), data acquisition module (2), control module (3), show load module (4), interface module (5) and memory module (6); Described external data detection module (1) is arranged on crane; Connect by the analog data signal and communication between described external data detection module (1) and data acquisition module (2); Be connected by ethernet communication between described data acquisition module (2) and control module (3); Described demonstration load module (4), interface module (5) and memory module (6) all are electrically connected to control module (3).
2. the safety assessment decision system of crane according to claim 1, it is characterized in that: described external data detection module (1) comprises the luffing pulling force sensor (11) for the luffing pulling force information of gathering project crane, the jib angular transducer (12) that is used for the jib angle information of gathering project crane, and the jib linear transducer (13) that is used for the jib length information of gathering project crane.
3. the safety assessment decision system of crane according to claim 2, it is characterized in that: the measurement range of the jib angular transducer (12) of described external data detection module (1) is 0 ° to 180 °.
4. the safety assessment decision system of crane according to claim 1, is characterized in that: the mechanical model database that stores the crane of various models in described memory module (6).
5. the safety assessment decision-making technique of the safety assessment decision system of crane is characterized in that: comprise the following steps:
1. luffing pulling force sensor (11), jib angular transducer (12), jib linear transducer (13) are sent to control module (3) with luffing pulling force information, jib angle information, the jib length information of crane respectively by data acquisition module (2);
2. the testing staff manually inputs the crane model to control module (3) by demonstration load module (4);
3. control module (3) is called the stress model of the crane of this model according to the model of crane from the mechanical model database, simultaneously according to luffing pulling force information, jib angle information and jib length information, by load-stress mapping relations, calculate and record pre-determined key structure point stress;
4. control module (3) by data recording, calculates the loading spectrum data of crane in a period of time;
5. the testing staff is according to the designing requirement of crane, and each key position of crane is carried out the emphasis monitoring, characterizes the safety index of whole crane with the force analysis of each key position of crane;
6. control module (3) is calculated respectively the position that the crane needs carry out Fatigue Life Assessment according to four kinds of estimating method for fatigue life; Described four kinds of estimating method for fatigue life are respectively nominal stress method based on fuzzy damage, Local Stress-Strain Method, based on the fracture mechanics method of finite element and the computing method that merge based on aforementioned three kinds of methods;
7. four kinds of methods calculate complete after, adopt corresponding Fatigue Summation Damage Theory that damage is accumulated, and finally calculate the fatigue lifetime that crane needs assessment site;
8. control module (3) according to cycle index and the load record of the requirement of crane design specifications, is calculated In-Service Engineering crane safe operation grade, and is provided suitable maintaining suggestion and safety assessment conclusion; Described assessment result comprises scrapping to be processed or demotes and use or keep in repair to use or continue and use safely.
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CN103323282A (en) * 2013-07-03 2013-09-25 贵州大学 Tower crane safety assessment method and assessment equipment thereof
CN103471755A (en) * 2013-09-04 2013-12-25 中联重科股份有限公司 Cantilever crane safety pre-warning method, device and system
CN103472819A (en) * 2013-09-12 2013-12-25 中国农业大学 Remote monitoring system for autocrane operation reliability tests
CN103593713A (en) * 2013-11-12 2014-02-19 三一汽车起重机械有限公司 Method and system for pressure analog prediction
CN103678908A (en) * 2013-12-10 2014-03-26 中联重科股份有限公司 Service-life early-warning method, service-life early-warning system and dynamic consolidation machine
CN109029815A (en) * 2018-08-13 2018-12-18 成都旸谷信息技术有限公司 Rolling stock key structure Fast Monitoring system
CN110954335A (en) * 2019-09-10 2020-04-03 郑州嘉晨电器有限公司 Health assessment method and system for industrial vehicle
CN111259494A (en) * 2020-01-08 2020-06-09 上海索辰信息科技有限公司 Health monitoring and analyzing method for heavy machine equipment
CN111562125A (en) * 2020-05-15 2020-08-21 海南省锅炉压力容器与特种设备检验所 Crane detection system and method based on vision and vibration
CN111977514A (en) * 2020-09-10 2020-11-24 河南省矿山起重机有限公司 Preventive maintenance system of crane based on Internet of things
CN113063615A (en) * 2021-03-22 2021-07-02 中海石油气电集团有限责任公司 Testing device and testing method for curved rail type crane
CN116448477A (en) * 2023-06-19 2023-07-18 临工重机股份有限公司 Telescopic arm forklift fault monitoring system and method

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CN103323282A (en) * 2013-07-03 2013-09-25 贵州大学 Tower crane safety assessment method and assessment equipment thereof
CN103471755A (en) * 2013-09-04 2013-12-25 中联重科股份有限公司 Cantilever crane safety pre-warning method, device and system
CN103471755B (en) * 2013-09-04 2016-04-13 中联重科股份有限公司 Arm support safe method for early warning, device and system
CN103472819A (en) * 2013-09-12 2013-12-25 中国农业大学 Remote monitoring system for autocrane operation reliability tests
CN103593713A (en) * 2013-11-12 2014-02-19 三一汽车起重机械有限公司 Method and system for pressure analog prediction
CN103678908A (en) * 2013-12-10 2014-03-26 中联重科股份有限公司 Service-life early-warning method, service-life early-warning system and dynamic consolidation machine
CN103678908B (en) * 2013-12-10 2017-01-25 中联重科股份有限公司 Service-life early-warning method, service-life early-warning system and dynamic consolidation machine
CN109029815A (en) * 2018-08-13 2018-12-18 成都旸谷信息技术有限公司 Rolling stock key structure Fast Monitoring system
CN110954335A (en) * 2019-09-10 2020-04-03 郑州嘉晨电器有限公司 Health assessment method and system for industrial vehicle
CN111259494A (en) * 2020-01-08 2020-06-09 上海索辰信息科技有限公司 Health monitoring and analyzing method for heavy machine equipment
CN111259494B (en) * 2020-01-08 2021-01-15 上海索辰信息科技股份有限公司 Health monitoring and analyzing method for heavy machine equipment
CN111562125A (en) * 2020-05-15 2020-08-21 海南省锅炉压力容器与特种设备检验所 Crane detection system and method based on vision and vibration
CN111977514A (en) * 2020-09-10 2020-11-24 河南省矿山起重机有限公司 Preventive maintenance system of crane based on Internet of things
CN113063615A (en) * 2021-03-22 2021-07-02 中海石油气电集团有限责任公司 Testing device and testing method for curved rail type crane
CN116448477A (en) * 2023-06-19 2023-07-18 临工重机股份有限公司 Telescopic arm forklift fault monitoring system and method
CN116448477B (en) * 2023-06-19 2023-09-01 临工重机股份有限公司 Telescopic arm forklift fault monitoring system and method

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