CN104760892B - Portal crane health monitoring and forecast visualization system - Google Patents

Portal crane health monitoring and forecast visualization system Download PDF

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Publication number
CN104760892B
CN104760892B CN201410005025.0A CN201410005025A CN104760892B CN 104760892 B CN104760892 B CN 104760892B CN 201410005025 A CN201410005025 A CN 201410005025A CN 104760892 B CN104760892 B CN 104760892B
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crane
data
monitoring
information
sensor
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CN104760892A (en
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丁克勤
肖竹军
王磊
张旭
陈力
陈�光
乔松
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CSEI
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C15/00Safety gear
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00Other constructional features or details
    • B66C13/16Applications of indicating, registering, or weighing devices

Abstract

The present invention provides a kind of portal crane health monitoring and forecast visualization system, including: sensor subsystem, information gathering and transmission subsystem, central server and system client;Sensor subsystem is used for obtaining crane real time execution parameter;Information gathering and transmission subsystem are for sending crane real time execution parameter to central server by wireless transmission unit;Central server is for carrying out storage and management to crane real time execution parameter, and then described crane is carried out Gernral Check-up, obtains health status diagnosis report;And predict whether described crane lost efficacy or broke down, and evaluates described crane safety in operation, obtains safety evaluation report according to diagnostic result;System client is used for showing the report of described crane real time execution parameter, described health status diagnosis and described safety evaluation report.The monitoring portal crane health status that energy is comprehensive, efficient, real-time, ensures the safe operation of portal crane.

Description

Portal crane health monitoring and forecast visualization system
Technical field
The invention belongs to health monitoring of equipment technical field, be specifically related to a kind of portal crane health monitoring with Forecast visualization system.
Background technology
Along with development and the raising of production complexity of national economy, portal crane transports at port and pier In play an important role, portal crane gradually towards maximize, the direction of function diversification develop, political affairs Mansion and society are more and more higher to the requirement of portal crane management of safe operation.
At present, portal crane safety management level also rests on reduced levels, mainly shows as following Aspect: 1) safety guarantee aspect, still based on regular inspection, prison inspection, the technological means used mostly is relative The range estimation, the sense organ that fall behind judge, shut down measurements, magnetic powder inspection etc., the workload of reviewer greatly but efficiency Relatively low, and the testing result under stopped status can not illustrate the ruuning situation under duty;2) harbour lifting Security monitoring and the management automation level of machine are low, still rely primarily on daily artificial spot check and periodic maintenance etc. and pass System mode, have that efficiency is low, poor real, information not comprehensively, the statistics and analysis etc. that is not easy to data asks Topic;3) existing portal crane monitoring system function singleness, it is impossible to grasp crane in real time, all sidedly and run Parameter, accordingly, it is difficult to crane carries out comprehensive effective monitoring, and then is difficult to ensure field personnel's peace Entirely.
Summary of the invention
The defect existed for prior art, the present invention provides a kind of portal crane health monitoring can with forecast Depending on change system, the monitoring portal crane health status that energy is comprehensive, efficient, real-time, ensure portal crane Safe operation.
The technical solution used in the present invention is as follows:
The present invention provides a kind of portal crane health monitoring and forecast visualization system, including: sense signals System, information gathering and transmission subsystem, central server and system client;
Described sensor subsystem is used for obtaining crane real time execution parameter;
Described information gathering and transmission subsystem are for gathering the described lifting that described sensor subsystem gets Machine real time execution parameter, and by wireless transmission unit, described crane real time execution parameter is sent to described Central server;
Described central server is transported in real time for receiving the crane from described information gathering with transmission subsystem Line parameter, carries out storage and management to described crane real time execution parameter, and then carries out described crane Gernral Check-up, obtains health status diagnosis report;And predict whether described crane lost efficacy according to diagnostic result Or break down, evaluate described crane safety in operation, obtain safety evaluation report;
Described system client is used for showing described crane real time execution parameter, described health status diagnosis report Accuse and described safety evaluation report.
Preferably, described sensor subsystem includes:
First kind sensor, is used for monitoring Mechanism of crane health status;
Equations of The Second Kind sensor, is used for monitoring crane structure health status;
Electric control system, is used for monitoring the electric health status of crane;
Intelligent label, is installed on crane key spot check position, is used for identifying crane key spot check position.
Preferably, described first kind sensor includes vibrating sensor, temperature sensor and displacement transducer; Described vibrating sensor for collection hoist/luffing/slew gear drive motor, hoist/luffing/slew gear subtracts The vibration signal of speed machine;Described temperature sensor is for gathering/the temperature of the luffing/slew gear reductor letter that hoists Number;Institute's displacement sensors is for gathering/the displacement signal of luffing/slewing gear brake that hoists;
Described Equations of The Second Kind sensor includes strain transducer, be used for gathering portal gantry shelf structure, upload post, Principal arm frame large arm, otic placode hinged place and the strain signal of otic placode root.
Preferably, described vibrating sensor is piezoelectric acceleration transducer, uses hole knockout, welding side Formula or magnetic pedestal mode are installed on the driving motor in each mechanism of portal crane and reductor, for perception Drive motor and the acceleration of vibration change information of reductor;The installation site of described vibrating sensor includes: The driving main motor output shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;Lifting mechanism/cart runs X, Y, Z outside X, Y, Z-direction, slow-speed shaft outside the reductor high speed shaft of mechanism/wheeling mechanism Direction;
Described temperature sensor is high heat conduction packaged type thermocouple, uses thread connecting mode to be installed to harbour and rises On reductor in each mechanism of heavy-duty machine, for the temperature information of perception each mechanism reductor lubricating oil;Institute The installation site stating temperature sensor includes: the reductor of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism Slow-speed shaft oil sealing hole;
Institute's displacement sensors is high accuracy linear type displacement sensor, uses bolt fixed mode to be installed to port In brake in the mouth each mechanism of crane, for the displacement information of perception brake block;Described displacement passes The installation site of sensor includes: on the brake block of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described strain transducer is from temperature compensation fiber Bragg grating strain sensor, uses welding manner to be installed to steel knot On structure;Concrete installation site is: on the web of described girder/auxiliary girder/end carriage or cover plate/and traveling mechanism of the larger traveller/little On the wheel of car travelling mechanism/movable pulley of lifting mechanism or fixed pulley on;
Described intelligent label uses high-frequency RF ID radio-frequency card, uses mounting means of pasting or punch to be installed on lifting Office key spot check position, for numbering accordingly crucial spot check position.
Preferably, described information gathering includes with transmission subsystem: vibration signals collecting unit, temperature signal Collecting unit, displacement signal acquisition unit, strain signal collecting unit, electrical control signal collecting unit, Intelligence spot check terminal and information transmission system;Described information transmission system respectively with described vibration signals collecting list Unit, temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit and intelligence spot check are eventually End connects;
Wherein, described vibration signals collecting unit, described temperature signal collection unit, institute's displacement signal are adopted Collection unit and described strain signal collecting unit gather the vibration of respective sensor, temperature, displacement respectively and answer Varying signal, and upload to described central server by described information transmission system;
Described intelligence spot check terminal built-in has rfid interrogator, for reading the volume of described smart tag memory storage Number information, and directly upload to described central server by wireless transmission unit;
Described electrical control signal collecting unit is for gathering the electric signal of electric control system, and passes through institute State information transmission system and upload to described central server.
Preferably, described information transmission system includes: data buffering queue, data server, Redis service Device and monitor client;
Described data buffering queue is as the data relay server between each sensor and data server, negative Duty buffering from each sensor acquisition of crane to Monitoring Data, and timing by this Monitoring Data send to number According to server;
Described data server includes that data receiver, data parser and data provide end;Described data connect Receiving end provides data decryptor port, the Monitoring Data that the transmission port for monitored data buffer queue is sent, And utilizing data parser that Monitoring Data is resolved, the data after resolving are stored in described Redis service Device;Described data provide end to provide service as Web server for monitor client;When monitor client is sent out When sending Monitoring Data to ask described data server, described data provide end to read monitoring from Redis server Data return to described monitor client as response.
Preferably, described central server includes: safety archive management module, intelligence spot check module, mechanism Health monitoring module, monitoring structural health conditions module, electric health monitoring module, Gernral Check-up forecast module and Safety evaluatio module;
Described safety archive management module: safeguard port crane safe practice archives for display and management, And provide user to input and management interface;Inputted and management interface by described user, receive portal crane Tool safe practice archives, are inquired about by described system client, are shown and safeguard that described port crane is pacified Full technology files;Wherein, described port crane safe practice archives include the electronic chart of portal crane Paper, basic parameter information table and major maintenance transformation record information;
Described intelligence spot check module: for showing the intelligent inspection information of port crane key position, and User's input and management interface are provided;
Described mechanism health monitoring module: for showing the real-time prison of port crane each mechanism operation conditions Measurement information, and failure mechanisms is carried out early warning and warning;
Described monitoring structural health conditions module: monitor letter in real time for show each constructional aspect of port crane Breath, and structural failure is carried out early warning and warning;
Described electric health monitoring module: for showing the reality of port crane electric control system operation conditions Time monitoring information, and electrical malfunction is carried out early warning and warning;
Described Gernral Check-up forecast module: be used for showing each mechanism of port crane, structure, electrical control system The diagnosis report of system, and the Gernral Check-up report that port crane complete machine is overall;
Described safety evaluatio module: be used for showing each mechanism of port crane, structure, electrical control The safety evaluation result of system, and the safety evaluation result that complete machine is overall.
Preferably, described central server structure MYSQL database cluster, redis data-base cluster and MongoDB data-base cluster;By described MYSQL database cluster, distributed storage initial data and Analysis result data;By described redis data-base cluster, distributed storage real time data;By described MongoDB data-base cluster, distributed storage document data.
Beneficial effects of the present invention is as follows:
The portal crane health monitoring that the present invention provides and forecast visualization system, with advanced sensing technology, Based on intelligence repair and maintenance management technique, monitoring and prediction technology and Safety Evaluation Technology, combine Internet of Things, cloud The advanced information technology such as platform, big data mining, overcomes traditional portal crane management of safe operation and deposits Efficiency is low, poor real, monitoring information not comprehensively, the problem such as control function is single, be simultaneously achieved The diagnosis of portal crane health operation conditions and Function of Evaluation, it is possible in time forecast crane mechanical breakdown and The generation of security incident, for ensureing the safe operation of portal crane, promoting the bursting tube of portal crane Reason level, raising port enterprise economic benefit etc. have great importance.
Accompanying drawing explanation
Fig. 1 for the present invention provide portal crane health monitoring with forecast visualization system overall structure Schematic diagram;
The flow chart of the information transmission system data handling procedure that Fig. 2 provides for the present invention;
The data storage rack composition of the central server structure that Fig. 3 provides for the present invention.
Detailed description of the invention
Below in conjunction with accompanying drawing, the present invention is described in detail:
The present invention provides a kind of portal crane health monitoring and forecast visualization system, mainly to harbour lifting The health status of machinery is monitored in real time, Gernral Check-up, healthy forecast and health control etc..Concrete, Including: sensor subsystem, information gathering and transmission subsystem, central server and system client four Part, it is achieved monitoring structural health conditions, mechanism's health monitoring and electrically health monitoring, and based on the number monitored Diagnose according to the health status of portal crane, its safety is evaluated.As it is shown in figure 1, be Portal crane health monitoring and the overall structure schematic diagram forecasting visualization system, described further below:
(1) sensor subsystem
Sensor subsystem is used for obtaining crane real time execution parameter, including: first kind sensor, it is used for Monitoring Mechanism of crane health status;Equations of The Second Kind sensor, is used for monitoring crane structure health status;Electricity Gas control system, is used for monitoring the electric health status of crane;Intelligent label, is installed on crane key point Inspection position, is used for identifying crane key spot check position.
Wherein, first kind sensor includes vibrating sensor, temperature sensor and displacement transducer;Described shake Dynamic sensor for gather hoist/luffing/slew gear drives motor, hoist/luffing/slew gear reductor Vibration signal;Described temperature sensor is for gathering/the temperature signal of luffing/slew gear reductor that hoists;Institute Displacement sensors is for gathering/the displacement signal of luffing/slewing gear brake that hoists;
Equations of The Second Kind sensor includes strain transducer, is used for gathering portal gantry shelf structure, uploading post, principal arm Frame large arm, otic placode hinged place and the strain signal of otic placode root.
It addition, in actual application, vibrating sensor is piezoelectric acceleration transducer, employing hole knockout, Welding manner or magnetic pedestal mode are installed on the driving motor in each mechanism of portal crane and reductor, use Acceleration of vibration change information in awareness driven motor and reductor;The installation site of described vibrating sensor Include but not limited to: the driving main motor output shaft of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;Rise Rise X, Y, Z-direction, low speed outside the reductor high speed shaft of mechanism/traveling mechanism of the larger traveller/wheeling mechanism X, Y, Z-direction outside axle;
Temperature sensor is high heat conduction packaged type thermocouple, uses thread connecting mode to be installed to portal crane On reductor in each mechanism, for the temperature information of perception each mechanism reductor lubricating oil;Described temperature The installation site of degree sensor includes but not limited to: subtracting of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism Speed machine slow-speed shaft oil sealing hole;
Displacement transducer is high accuracy linear type displacement sensor, uses bolt fixed mode to be installed to harbour and rises In brake in each mechanism of heavy-duty machine, for the displacement information of perception brake block, such as operating state, OK Cheng Weiyi;The installation site of institute's displacement sensors includes but not limited to: lifting mechanism/traveling mechanism of the larger traveller/little On the brake block of car travelling mechanism;
Described strain transducer is from temperature compensation fiber Bragg grating strain sensor, uses welding manner to be installed to steel knot On structure;Installation site includes but not limited to: on the web of described girder/auxiliary girder/end carriage or cover plate/and cart operation machine On the wheel of structure/wheeling mechanism/movable pulley of lifting mechanism or fixed pulley on;
Intelligent label uses high-frequency RF ID radio-frequency card, uses mounting means of pasting or punch to be installed on crane day The position of spot check is needed, for numbering spot check position so that identifying accordingly in often running and safeguarding.
(2) information gathering and transmission subsystem
Information gathering and transmission subsystem are for gathering the crane real time execution that sensor subsystem gets Parameter, and by wireless transmission unit, crane real time execution parameter is sent to central server.
Information gathering includes with transmission subsystem: vibration signals collecting unit, temperature signal collection unit, position Shifting signal collecting unit, strain signal collecting unit, electrical control signal collecting unit, intelligence spot check terminal And information transmission system;Described information transmission system respectively with described vibration signals collecting unit, temperature signal Collecting unit, displacement signal acquisition unit, strain signal collecting unit, intelligence spot check terminal connect;Wherein, Vibration signals collecting unit, temperature signal collection unit, displacement signal acquisition unit and strain signal gather single Unit gathers the vibration of respective sensor, temperature, displacement and strain signal respectively, and is transmitted by described information System uploads to described central server;Intelligence spot check terminal built-in has rfid interrogator, is used for reading described The number information of smart tag memory storage, and directly upload to described central server by wireless transmission unit.
Basic parameter and the technical specification of each collecting unit are as follows:
(1) vibration signals collecting cell parameters:
Project Parameter
Port number: 4~16CH
Input: Preposition conditioner
Bandwidth chahnel: 0~100KHz
A/D resolution: 16bit
Signal to noise ratio: ≥72dB
Data transfer mode: USB
Sample frequency: Continuous acquisition 100KSPS/CH, stepping is optional
Anti-aliasing protection: ≥100dB
Sampling length: Mass memory (depends on hard disc of computer space size)
Triggering mode: Single channel internal trigger
Analog input voltage scope: ±5VP
Operating temperature range: -40℃-120℃
(2) temperature signal collection cell parameters:
(3) position signal acquisition cell parameters:
Measurement scope: 0-10cm (customizable)
Resolution: 0.1mm
Frequency acquisition: 10K (can be arranged)
Number of channels: 6 passages
Temperature: -60-+150℃
Maximum operating speed: 10m/s
Impact coefficient: IEC68-2-29:1968 50g
Oscillating Coefficients: IEC68-2-6:1982 20g
Repeatability error: ≤0.005mm
Linear precision error: ≤ 0.05%
Temperature coefficient: < 1.5ppm/ DEG C
Other performances Dustproof and waterproof is grease proofing shockproof
(4) strain signal collecting unit parameter:
Strain signal collecting unit uses the GTS-ASHM-001 health monitoring (FBG) demodulator of independent research, can fit For polytype fiber-optic grating sensor signal demodulation such as optical fiber grating temperature, strain, pressure, displacements With sensing data dynamic acquisition it can also be used to the high speed signal of optical fiber acceleration transducer demodulates and data acquisition. This health monitoring (FBG) demodulator uses scan laser and parallel spectrum Detection Techniques, and source device output optical power utilizes Rate is up to more than 85%, compares traditional ASE+ tunable filter technology, and light source output power improves 100 More than Bei, power supply power consumption then declines 50%, and light source Acceptable life improves more than 10 years.Wherein, mainly Performance indications are as shown in the table.
(5) intelligence spot check terminal parameter:
(3) central server
Central server is for receiving the crane real time execution ginseng from described information gathering with transmission subsystem Number, carries out storage and management to described crane real time execution parameter, and then described crane is carried out health Diagnosis, obtains health status diagnosis report;And predict whether described crane lost efficacy or sent out according to diagnostic result Raw fault, evaluates described crane safety in operation, obtains safety evaluation report.
Concrete, central server includes: safety archive management module, intelligence spot check module, mechanism's health Monitoring modular, monitoring structural health conditions module, electric health monitoring module, Gernral Check-up forecast module and safety Property evaluation module;
Safety archive management module: safeguard port crane safe practice archives for display and management, and User's input and management interface are provided;Inputted and management interface by described user, receive port crane Safe practice archives, are inquired about by described system client, are shown and safeguard described port crane safety Technology files;Wherein, described port crane safe practice archives include portal crane electronic drawing, Basic parameter information table and major maintenance transformation record information;Module is managed, it is simple to right by safety archive The carrying out of portal crane safe practice document is managed collectively, information sharing, can be portal crane simultaneously Parts replacement, failure analysis, health assessment provide effective reference.
Intelligence spot check module: for showing the intelligent inspection information of port crane key position, and provide User's input and management interface;By intelligence spot check module, information technology and handheld mobile device is used to realize The spot check standardization of port crane daily repair and maintenance spot check project, simple operation, data validation, Record is with no paper, supervises scientific, information sharing, it is possible to is obviously improved hoisting machinery and uses unit management Level and the use safety of equipment;
Mechanism's health monitoring module: monitor letter in real time for show port crane each mechanism operation conditions Breath, and point out user to contingent failure mechanisms in sound and light alarm mode.By mechanism's health monitoring mould Block, can monitor the operation conditions of each mechanism of portal crane in real time, to contingent failure mechanisms can and Time early warning, to reduce economic loss, reduce security incident significant;
Monitoring structural health conditions module: for showing the real-time monitoring information of each constructional aspect of port crane, And point out user to the inefficacy of contingent frame for movement in sound and light alarm mode.By monitoring structural health conditions mould Block, can monitor each constructional aspect of portal crane in real time, and losing efficacy contingent frame for movement can be timely Early warning, to reducing economic loss, reduces security incident significant;
Electrically health monitoring module: for showing the real-time of port crane electric control system operation conditions Monitoring information, and point out user to contingent electrical malfunction in sound and light alarm mode.By electrically Health monitoring module, can monitor the operation conditions of portal crane electric control system in real time, to it may happen that Electric fault can early warning in time, to reduce economic loss, reduce security incident significant;
Gernral Check-up forecast module: for showing port crane each mechanism, structure, electric control system Diagnosis report, and the Gernral Check-up report that port crane complete machine is overall;Mould is forecast by Gernral Check-up Block, it is possible to mechanism each to crane, structure, the health status of electrical system are passed judgment on, diagnosed, thus The holistic health of crane can be grasped accurately and real-time, for the warp avoiding sudden shutdown to cause The prevention of Ji loss and security incident is significant;
Safety evaluatio module: be used for showing each mechanism of port crane, structure, electric control system Safety evaluation result, and the safety evaluation result that complete machine is overall.Take analytic hierarchy process (AHP) and obscure comprehensive Closing the strategy of judge method reasonable combination, the advantage giving full play to the two makes up the other side's deficiency, it is possible to more reasonable Ground realizes the objective evaluation of substantial equipment this for portal crane.
(4) system client
System client is used for crane real time execution parameter, health status diagnosis report, safety evaluation report, And the display of predicting residual useful life report exports and management function.
The portal crane health monitoring that the present invention provides and forecast visualization system, specific works flow process includes Following step:
Step 1: obtain crane health information
Crane health information is obtained by following components: collects safe practice archive information, adopt Collection key position inspection information, collecting mechanism operation information, collection constructional aspect information, collection electrical control System operation information.Wherein the specific implementation method of each several part acquisition of information is:
The collection of safe practice archive information: by the electronic drawing of portal crane, basic parameter information table with And major maintenance transformation record etc., directly by systems soft ware typing central server.
The collection of key position inspection information: utilize the intelligence that intelligence spot check terminal scanning is installed on crane Label, reading area information and spot check project, during spot check result can be uploaded to by wired or wireless mode Central server stores.
The collection of mechanism's operation information: by the lifting mechanism of crane, jib lubbing mechanism, rotating mechanism and Corresponding sensor and signal gathering unit are installed in walking mechanism, obtain the operation conditions of each mechanism of crane Information.Wherein, use vibrating sensor, temperature sensor to obtain in each mechanism to drive motor, reductor Vibration, bearing temperature information, use position sensor to obtain brake block stroke and the shape of each gear brake State information.
The collection of constructional aspect information: by the door frame of crane, rotating disk, upload post, balance system, Corresponding sensor is installed on the steel constructions such as principal arm frame, gathers the real time status letter of each main steel construction of crane Breath.Wherein, the deformation of weld seam between the employing strain transducer acquisition each main steel construction of crane and steel construction, Strain information, uses acoustic emission sensor to obtain the Crack Damage information of each main steel construction of crane.
The collection of electrical system information: believe by directly reading the control of electric control system PLC on crane Number, obtain the real-time traffic information of crane electrical system.
Step 2: the transmission of crane health information, storage.
The acquired each mechanism of crane, structure, the health information of electrical system all pass through wireless transmission Module transfer stores to central server, and acquired key position inspection information is directly by intelligence spot check Terminal sends to central server through wired or wireless mode and stores.Wherein, intelligence spot check terminal can Think Intelligent handhold instrument.Transmission and the storage scheme of information are respectively as follows:
Information transmission scheme:
As in figure 2 it is shown, information transmission system data handling procedure is:
Information transmission system includes: data buffering queue, data server, Redis server and monitoring client Hold four parts;Wherein, Redis server be a use ANSI C language increased income write, support network, Can based on internal memory also can the log type of persistence, Key-Value data base, data buffering queue is as each sensing Data relay server between device and data server, be responsible for buffering from each sensor acquisition of crane to Monitoring Data, and timing by this Monitoring Data send to data server;
Described data server includes that data receiver, data parser and data provide end;Described data connect Receiving end provides data decryptor port, the Monitoring Data that the transmission port for monitored data buffer queue is sent, And utilizing data parser that Monitoring Data is resolved, the data after resolving are stored in described Redis server; Described data provide end to provide service as Web server for monitor client;When monitor client sends monitoring When request of data is to described data server, described data provide end to read Monitoring Data work from Redis server Described monitor client is returned to for response.
The scheme of information storage is:
In the present invention, the data storage architecture of central server structure is as it is shown on figure 3, include that MYSQL (closes Be type data base management system) data-base cluster, redis data-base cluster and MongoDB (distribution type file Storage data base) data-base cluster;By described MYSQL database cluster, distributed storage user make The initial data higher by frequency and analysis result data;By described redis data-base cluster, distributed deposit Storage real time data;By described MongoDB data-base cluster, distributed storage document data, thus protect Barrier system throughput in data, services and storage efficiency.
Step 3: the diagnosis of crane health status, evaluate and forecast.
After central server obtains the health information of crane, first with signal processing method, mould The formula recognition methods information to being obtained carries out pretreatment and fault signature extracts, and then integrated use damage is lost Effect analysis method, Fault Tree Analysis, method for evaluating reliability, analytic hierarchy process (AHP) and fuzzy synthesis are commented Sentence method, portal crane is carried out the diagnosis of health status, inefficacy or the forecast of fault and safety Evaluate, demonstrate the real time data of portal crane operation conditions, Gernral Check-up finally by system client Report, safety evaluation report.
In sum, the portal crane health monitoring that the present invention provides and forecast visualization system, with advanced person Sensing technology, intelligence repair and maintenance management technique, based on monitoring and prediction technology and Safety Evaluation Technology, in conjunction with The advanced information technologys such as Internet of Things, cloud platform, big data mining, overcome traditional portal crane peace The problems such as the efficiency that full management work exists is low, poor real, monitoring information are comprehensive, control function is single, It is simultaneously achieved diagnosis and the Function of Evaluation of portal crane health operation conditions, it is possible to forecast crane in time Mechanical breakdown and the generation of security incident, for ensureing the safe operation of portal crane, promoting harbour lifting The safety management level of machine, raising port enterprise economic benefit etc. have great importance.
The above is only the preferred embodiment of the present invention, it is noted that common for the art For technical staff, under the premise without departing from the principles of the invention, it is also possible to make some improvements and modifications, These improvements and modifications also should regard protection scope of the present invention.

Claims (3)

1. a portal crane health monitoring and forecast visualization system, it is characterised in that including: sensing Device subsystem, information gathering and transmission subsystem, central server and system client;
Described sensor subsystem is used for obtaining crane real time execution parameter;
Described information gathering and transmission subsystem are for gathering the described lifting that described sensor subsystem gets Machine real time execution parameter, and by wireless transmission unit, described crane real time execution parameter is sent to described Central server;
Described central server is transported in real time for receiving the crane from described information gathering with transmission subsystem Line parameter, carries out storage and management to described crane real time execution parameter, and then carries out described crane Gernral Check-up, obtains health status diagnosis report;And predict whether described crane lost efficacy according to diagnostic result Or break down, evaluate described crane safety in operation, obtain safety evaluation report;
Described system client is used for showing described crane real time execution parameter, described health status diagnosis report Accuse and described safety evaluation report;
Wherein, described sensor subsystem includes:
First kind sensor, is used for monitoring Mechanism of crane health status;
Equations of The Second Kind sensor, is used for monitoring crane structure health status;
Electric control system, is used for monitoring the electric health status of crane;
Intelligent label, is installed on crane key spot check position, is used for identifying crane key spot check position;
Wherein, described first kind sensor includes vibrating sensor, temperature sensor and displacement transducer;Institute State vibrating sensor for gather hoist/luffing/slew gear drive motor, hoist/luffing/slew gear slows down The vibration signal of machine;Described temperature sensor is for gathering/the temperature of the luffing/slew gear reductor letter that hoists Number;Institute's displacement sensors is for gathering/the displacement signal of luffing/slewing gear brake that hoists;
Described Equations of The Second Kind sensor includes strain transducer, be used for gathering portal gantry shelf structure, upload post, Principal arm frame large arm, otic placode hinged place and the strain signal of otic placode root;
Wherein, described vibrating sensor is piezoelectric acceleration transducer, uses hole knockout, welding manner Or magnetic pedestal mode is installed on the driving motor in each mechanism of portal crane and reductor, drive for perception The acceleration of vibration change information of galvanic electricity machine and reductor;The installation site of described vibrating sensor includes: rise Rise the driving main motor output shaft of mechanism/traveling mechanism of the larger traveller/wheeling mechanism;Lifting mechanism/cart runs machine X, Y, Z side outside X, Y, Z-direction, slow-speed shaft outside the reductor high speed shaft of structure/wheeling mechanism To;
Described temperature sensor is high heat conduction packaged type thermocouple, uses thread connecting mode to be installed to harbour and rises On reductor in each mechanism of heavy-duty machine, for the temperature information of perception each mechanism reductor lubricating oil;Institute The installation site stating temperature sensor includes: the reductor of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism Slow-speed shaft oil sealing hole;
Institute's displacement sensors is high accuracy linear type displacement sensor, uses bolt fixed mode to be installed to port In brake in the mouth each mechanism of crane, for the displacement information of perception brake block;Described displacement passes The installation site of sensor includes: on the brake block of lifting mechanism/traveling mechanism of the larger traveller/wheeling mechanism;
Described strain transducer is from temperature compensation fiber Bragg grating strain sensor, uses welding manner to be installed to steel knot On structure;Concrete installation site is: on the web of girder/auxiliary girder/end carriage or cover plate/and traveling mechanism of the larger traveller/dolly fortune On the wheel of row mechanism/movable pulley of lifting mechanism or fixed pulley on;
Described intelligent label uses high-frequency RF ID radio-frequency card, uses mounting means of pasting or punch to be installed on lifting Office key spot check position, for numbering accordingly crucial spot check position;
Wherein, described information gathering includes with transmission subsystem: vibration signals collecting unit, temperature signal are adopted Collection unit, displacement signal acquisition unit, strain signal collecting unit, electrical control signal collecting unit, intelligence Can spot check terminal and information transmission system;Described information transmission system respectively with described vibration signals collecting unit, Temperature signal collection unit, displacement signal acquisition unit, strain signal collecting unit and intelligence spot check terminal are even Connect;
Wherein, described vibration signals collecting unit, described temperature signal collection unit, institute's displacement signal are adopted Collection unit and described strain signal collecting unit gather the vibration of respective sensor, temperature, displacement respectively and answer Varying signal, and upload to described central server by described information transmission system;
Described intelligence spot check terminal built-in has rfid interrogator, for reading the volume of described smart tag memory storage Number information, and directly upload to described central server by wireless transmission unit;
Described electrical control signal collecting unit is for gathering the electric signal of electric control system, and passes through institute State information transmission system and upload to described central server;
Wherein, described information transmission system includes: data buffering queue, data server, Redis server And monitor client;
Described data buffering queue is as the data relay server between each sensor and data server, negative Duty buffering from each sensor acquisition of crane to Monitoring Data, and timing by this Monitoring Data send to number According to server;
Described data server includes that data receiver, data parser and data provide end;Described data connect Receiving end provides data decryptor port, the Monitoring Data that the transmission port for monitored data buffer queue is sent, And utilizing data parser that Monitoring Data is resolved, the data after resolving are stored in described Redis service Device;Described data provide end to provide service as Web server for monitor client;When monitor client is sent out When sending Monitoring Data to ask described data server, described data provide end to read monitoring from Redis server Data return to described monitor client as response.
Portal crane health monitoring the most according to claim 1 and forecast visualization system, its feature Being, described central server includes: safety archive management module, intelligence spot check module, mechanism's health prison Survey module, monitoring structural health conditions module, electric health monitoring module, Gernral Check-up forecast module and safety Evaluation module;
Described safety archive management module: safeguard portal crane safe practice archives for display and management, And provide user to input and management interface;Inputted and management interface by described user, receive portal crane Safe practice archives, are inquired about by described system client, are shown and safeguard the safe skill of described portal crane Art archives;Wherein, described portal crane safe practice archives include the electronic drawing of portal crane, base This parameter information table and major maintenance transformation record information;
Described intelligence spot check module: for showing the intelligent inspection information of portal crane key position, and carry For user's input and management interface;
Described mechanism health monitoring module: for showing the real-time monitoring of portal crane each mechanism operation conditions Information, and failure mechanisms is carried out early warning and warning;
Described monitoring structural health conditions module: for showing the real-time monitoring information of each constructional aspect of portal crane, And structural failure is carried out early warning and warning;
Described electric health monitoring module: for showing the real-time of portal crane electric control system operation conditions Monitoring information, and electrical malfunction is carried out early warning and warning;
Described Gernral Check-up forecast module: be used for showing each mechanism of portal crane, structure, electric control system Diagnosis report, and portal crane complete machine overall Gernral Check-up report;
Described safety evaluatio module: be used for showing each mechanism of portal crane, structure, electrical control system The safety evaluation result of system, and the safety evaluation result that complete machine is overall.
Portal crane health monitoring the most according to claim 1 and forecast visualization system, its feature It is, described central server structure MYSQL database cluster, redis data-base cluster and MongoDB Data-base cluster;By described MYSQL database cluster, distributed storage initial data and analysis result Data;By described redis data-base cluster, distributed storage real time data;By described MongoDB Data-base cluster, distributed storage document data.
CN201410005025.0A 2014-01-06 2014-01-06 Portal crane health monitoring and forecast visualization system Expired - Fee Related CN104760892B (en)

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