CN104760893A - Metallurgical lifting machinery operation safety machine-mounted early warning system - Google Patents

Abstract

The invention provides an airborne early warning system for metallurgical hoisting machinery operation safety, comprising: a data acquisition layer, a data transmission layer, and an industrial computer; the industrial computer includes a data acquisition interface, a data monitoring module, and an early warning module; wherein, the data The collection layer is used to collect the operation safety parameters of the monitored metallurgical hoisting machinery, and transmits them to the data collection interface of the industrial computer through the data transmission layer; the data monitoring module is used to monitor the data received by the data collection interface Parameters; the early warning module is used to analyze the parameters received by the data collection interface and give early warning. The airborne early warning system for metallurgical hoisting machinery operation safety can comprehensively and effectively monitor the operation safety status of metallurgical hoisting machinery, and realize effective long-term health monitoring of metallurgical hoisting machinery.

Description

Airborne early warning system for metallurgical hoisting machinery operation safety

technical field

The invention belongs to the technical field of equipment health monitoring, and in particular relates to an airborne early warning system for the operation safety of metallurgical hoisting machinery.

Background technique

The working environment of metallurgical hoisting machinery is very harsh, and most of them are in high temperature and high dust working environment. Once a failure occurs, the consequences are often very serious. For example, at 7:53 on April 18, 2007, a molten steel ladle overturned in the steelmaking workshop of Qinghe Special Steel Co., Ltd., Tieling City, Liaoning Province, resulting in 32 deaths and 6 serious injuries, causing serious social impact.

In order to reduce the probability of accidents in metallurgical hoisting machinery, it is necessary to monitor the operating status of metallurgical hoisting machinery. However, the existing metallurgical hoisting machinery has a low level of safety monitoring and management automation, and the monitored operating parameters are not comprehensive, so it is difficult to monitor the metallurgical hoisting machinery. Effective long-term health monitoring of machinery.

Contents of the invention

Aiming at the defects existing in the prior art, the present invention provides an airborne early warning system for the operation safety of metallurgical hoisting machinery, which can comprehensively and effectively monitor the operation safety status of metallurgical hoisting machinery, and realize effective long-term health monitoring of metallurgical hoisting machinery.

The technical scheme that the present invention adopts is as follows:

The invention provides an airborne early warning system for metallurgical hoisting machinery operation safety, comprising: a data acquisition layer, a data transmission layer, and an industrial computer; the industrial computer includes a data acquisition interface, a data monitoring module, and an early warning module;

Wherein, the data collection layer is used to collect the operation safety parameters of the monitored metallurgical hoisting machinery, and transmits to the data collection interface of the industrial computer through the data transmission layer; the data monitoring module is used to monitor the data collection The parameters received by the interface; the early warning module is used to analyze the parameters received by the data collection interface and give an early warning.

Preferably, the data acquisition layer includes a sensing layer and a signal processor;

The sensing layer includes a PLC controller, a vibration sensor and a temperature sensor; wherein, the PLC controller is a controller configured by the monitored metallurgical hoisting machinery itself; the vibration sensor is used to collect the vibration signal of the reducer; the The temperature sensor is used to collect the temperature signal of the reducer;

The signal processor is used to collect the output signal of the PLC controller, and is transmitted to the data acquisition interface of the industrial computer through the data transmission layer; the signal processor is also used for the speed reducer output by the temperature sensor The temperature signal is filtered, adjusted and converted from analog to digital, and then sent to the data acquisition interface of the industrial computer; the signal processor is also used to filter, adjust and modulo the vibration signal of the reducer output by the vibration sensor. conversion processing, and then send to the data acquisition interface of the industrial computer.

Preferably, the vibration sensor adopts a piezoelectric acceleration sensor, which is equipped with a charge amplifier itself, and its power supply and signal output share a coaxial cable; it has a magnetic suction seat, and the vibration sensor is installed on the On the reducer box at the shaft end of the metallurgical hoisting machinery reducer.

Preferably, the temperature sensor is a platinum resistance temperature sensor PT100, which is installed on the reducer case at the shaft end of the reducer through screw connection.

Preferably, the signal processor collects the parameters output by the temperature sensor and the vibration sensor by the following methods:

The signal processor creates a device object handle for absolute control of a certain controlled device;

The signal processor sets a sampling parameter corresponding to each sampling channel, and the sampling parameter includes a sampling frequency and a sensor type corresponding to the sampling channel;

The signal processor reads the analog data transmitted by a certain sampling channel according to the sampling frequency, and then performs analog-to-digital conversion on the analog data to realize continuous and uninterrupted cyclic sampling;

When it is necessary to read the data transmitted by other sampling channels, modify the sampling channel and sampling frequency parameters, and repeat the above cyclic sampling process;

When it is necessary to stop sampling, release the device object handle.

Preferably, the signal processor collects the output signal of the PLC controller by the following method:

The signal processor creates a device object handle for absolute control of a certain controlled device; wherein, the controlled device is equipped with a PLC controller;

Initialize the sampling channel between the signal processor and the PLC controller;

The signal processor directly reads the parameters stored inside the PLC controller.

Preferably, the output signal of the PLC controller includes: monitoring parameters and monitoring status;

The monitoring parameters include: main lifting/auxiliary lifting/auxiliary lifting weight, lifting height, working time and corresponding operating instructions, the operating instructions include lifting instructions, stop instructions or lowering instructions; The monitoring parameters also include the running stroke of the cart/main trolley/auxiliary trolley, safety distance and corresponding operating instructions, which include left-moving instructions, right-moving instructions and stop instructions;

The monitoring state includes the braking state of the main lift/auxiliary lift/auxiliary hoist, the door limit interlock protection state and the inter-mechanism operation interlock protection state; The braking state of hoisting is the state of whether the brake is open or not;

The working time counts the start action time, end action time and working time period of the main hoist/auxiliary hoist/auxiliary hoist/truck/main trolley/auxiliary trolley.

Preferably, the data monitoring module includes a data display submodule, a data storage submodule and a data playback submodule;

The data display sub-module is used to display the operation safety parameters of the metallurgical hoisting machinery in real time, and is also used to display the safety status of the monitored metallurgical hoisting machinery; the data storage sub-module is used to classify and store the corresponding The operation safety parameters; the data playback sub-module is used to call the operation safety history data of any historical time.

Preferably, the early warning module includes a threshold setting submodule and an overrun alarm submodule;

The threshold setting submodule is used to set the operation safety limit value of each monitoring parameter;

The overrun alarm sub-module is used to issue an alarm when the received monitoring parameter exceeds a corresponding threshold.

Preferably, the overrun alarm sub-module includes a control circuit and several driving circuits; the control circuit is used to communicate with the industrial computer, and when the monitoring value received by the industrial computer exceeds a preset threshold, it sends The control circuit sends out a driving signal; when the control circuit receives the driving signal, it drives the corresponding driving circuit to give an audible and visual alarm.

The beneficial effects of the present invention are as follows:

The metallurgical hoisting machinery operation safety airborne early warning system provided by the present invention realizes the operation parameters such as the lifting weight, lifting height/falling depth, and operating stroke of the metallurgical hoisting machinery, and the working status of the hoisting mechanism brake, door limit, etc. , as well as the real-time monitoring and early warning of multiple parameters such as the vibration of the reducer and the bearing temperature, and can record and view data in real time on various operating parameters, working conditions, operating instructions, and alarm conditions to prevent or eliminate operational safety caused by failures question. It solves the current problems in the operation safety of metallurgical cranes, improves the operation safety monitoring level of metallurgical cranes, thereby ensuring the safe operation of the cranes and reducing the occurrence of major accidents.

Description of drawings

Fig. 1 is the overall structure schematic diagram of the metallurgical hoisting machinery operation safety airborne early warning system provided by the present invention;

Fig. 2 is the schematic flow sheet of gathering PLC controller output signal that the present invention provides;

Fig. 3 is the schematic flow chart of collecting temperature sensor and vibration sensor output parameters provided by the present invention;

Fig. 4 is the schematic structural diagram of the industrial computer provided by the present invention;

Fig. 5 is a circuit diagram of the control circuit provided by the present invention.

Detailed ways

The present invention is described in detail below in conjunction with accompanying drawing:

As shown in Figure 1, the present invention provides a kind of metallurgical hoisting machinery operation safety airborne early warning system, comprises: data acquisition layer, data transmission layer and industrial computer; Industrial computer comprises data acquisition interface, data monitoring module and early warning module;

Among them, the data acquisition layer is used to collect the operation safety parameters of the monitored metallurgical hoisting machinery, and transmit them to the data acquisition interface of the industrial computer through the data transmission layer; the data monitoring module is used to monitor the parameters received by the data acquisition interface; the early warning module is used to It is used to analyze the parameters received by the data collection interface and give an early warning.

The above modules are described in detail below:

(1) Data collection layer

The data acquisition layer includes a sensing layer and a signal processor. Specifically, the sensing layer is used to collect various monitoring signals collected by the PLC controller, the temperature signal of the reducer collected by the temperature sensor, and the vibration signal of the reducer collected by the vibration sensor, which are processed by the signal processor and uploaded to the industrial computer.

(1) Sensing layer

The sensing layer includes PLC controller, vibration sensor and temperature sensor.

(a) PLC controller

The PLC controller is the controller configured by the monitored metallurgical lifting machinery; the PLC controller is connected to the communication card in the industrial computer, and the industrial computer can read data according to the data storage structure and location in the PLC. The output signal of the PLC controller is shown in Table 1, including: monitoring parameters and monitoring status.

Among them, the monitoring parameters include: main lifting/auxiliary lifting/auxiliary lifting weight, lifting height, working time and corresponding operating instructions, the operating instructions include lifting instructions, stop instructions or lowering instructions; The monitoring parameters also include the running stroke of the cart/main trolley/auxiliary trolley, safety distance and corresponding operating instructions, which include left-moving instructions, right-moving instructions and stop instructions;

The monitoring status includes the braking status of the main hoist/auxiliary hoist/auxiliary hoist, the door limit interlock protection status and the operation interlock protection status between mechanisms; among them, the main hoist/auxiliary hoist/auxiliary hoist The braking state of is the state of whether the brake is open;

Working time statistics of the main lift/auxiliary lift/auxiliary hoist/cradle/main trolley/auxiliary trolley start action time, end action time and working time period.

Table 1 PLC controller output parameter list

(b) Vibration sensor

The vibration sensor is used to collect the vibration signal of the reducer. In the present invention, the vibration sensor adopts a piezoelectric acceleration sensor, which is equipped with a charge amplifier, and its power supply and signal output share a coaxial cable; it has a magnetic suction seat, and the vibration sensor is installed on the magnetic suction seat through the magnetic suction seat. On the reducer box at the shaft end of the metallurgical hoisting machinery reducer.

(c) Temperature sensor

The temperature sensor is used to collect the temperature signal of the reducer. In the present invention, the temperature sensor adopts a platinum resistance temperature sensor PT100, which is installed on the reducer box at the shaft end of the reducer through screw connection.

(2) Signal processor

(a) Processing of PLC controller output signal

The signal processor is used to collect the output signal of the PLC controller, and is transmitted to the data acquisition interface of the industrial computer by the data transmission layer, specifically the PLC data acquisition interface; as shown in Figure 2, the signal processor passes the following method Gather the output signal of the PLC controller:

S21, the signal processor creates a device object handle for absolute control of a certain controlled device; wherein, the controlled device is equipped with a PLC controller;

S22, initializing the sampling channel between the signal processor and the PLC controller;

S23. The signal processor directly reads the parameters stored inside the PLC controller.

(b) Processing of output signals of temperature sensor and vibration sensor

The signal processor is also used for filtering, conditioning and analog-to-digital conversion processing of the reducer temperature signal output by the temperature sensor, and then sent to the data acquisition interface of the industrial computer, specifically the temperature signal acquisition interface; the signal processor is also used for vibration The vibration signal of the reducer output by the sensor is filtered, adjusted and processed by analog-to-digital conversion, and then sent to the data acquisition interface of the industrial computer, specifically the vibration signal acquisition interface.

As shown in Figure 3, the signal processor collects the parameters output by the temperature sensor and the vibration sensor through the following methods:

S31. The signal processor creates a device object handle for absolute control of a controlled device; after the serial port of the controlled device is initialized, the device object handle can be passed as a parameter to other functions for use by other functions.

S32, the signal processor sets the sampling parameters corresponding to each sampling channel, and the sampling parameters include the sampling frequency and the sensor type corresponding to the sampling channel; for example, the temperature sensor corresponds to the first sampling channel and the first sampling frequency; the vibration sensor corresponds to the first sampling channel and the first sampling frequency; Second sampling channel and second sampling frequency.

S32, the signal processor reads the analog data transmitted by a certain sampling channel according to the sampling frequency, and then performs analog-to-digital conversion on the analog data to realize continuous and uninterrupted cyclic sampling;

S33, when it is necessary to read data transmitted by other sampling channels, modify the sampling channel and sampling frequency parameters, and repeat the above-mentioned cyclic sampling process;

S34, when it is necessary to stop sampling, release the handle of the device object and exit the collection loop.

(2) Industrial computer

As shown in Figure 4, it is a schematic structural diagram of an industrial computer, which includes a data acquisition interface, a data monitoring module and an early warning module;

(1) Data acquisition interface

The data acquisition interface includes: PLC data acquisition interface, vibration signal acquisition interface and temperature signal acquisition interface.

(2) Data monitoring module

The data monitoring module includes a data display submodule, a data storage submodule and a data playback submodule;

The data display sub-module is used to display the operation safety parameters of metallurgical hoisting machinery in real time, and is also used to display the safety status of the monitored metallurgical hoisting machinery;

The data storage sub-module is used to classify and store the operation safety parameters corresponding to each metallurgical hoisting machinery through the database; specifically, due to the large amount of data of the operation safety parameters, the database is used to manage the operation safety parameters. The database mainly manages monitoring parameters such as the output signal of the PLC controller, the vibration signal of the reducer, and the temperature signal of the reducer. In addition, it is also necessary to manage the basic information of the monitoring signal, the alarm threshold of monitoring parameters and other information, so as to realize the purpose of signal monitoring and data storage. Among them, the basic information of the monitoring signal includes the signal collection time, the crane number corresponding to the signal, and the like.

The data playback sub-module is used to retrieve the operation safety historical data at any historical time.

(3) Early warning module

The early warning module includes a threshold setting submodule and an overrun alarm submodule. Among them, the threshold setting sub-module is used to set the operation safety limit value of each monitoring parameter; the over-limit alarm sub-module is used to give an alarm when the received monitoring parameter exceeds the corresponding threshold. The user realizes the role of real-time early warning in the monitoring process by setting the alarm threshold. The over-limit alarm sub-module can use an audible and visual alarm module to perform an audible and visual alarm.

The early warning module can be connected with the industrial computer through a USB connection line, or can be a built-in module of the industrial computer. The software in the industrial computer sets the alarm value of each parameter, and compares the collected monitoring value with the alarm value. When the monitoring value exceeds the alarm value, the alarm module is driven to give an audible and visual alarm.

Specifically, the overrun alarm sub-module includes a control circuit and several driving circuits; the control circuit can use a single-chip microcomputer 89C51, on the one hand, it is used to communicate with the industrial computer, and when the monitoring value received by the industrial computer exceeds the preset threshold, it will send The control circuit sends out a driving signal; on the other hand, when the control circuit receives the driving signal, it drives the corresponding driving circuit to give an audible and visual alarm. The circuit diagram of the control circuit is shown in Figure 5: the CPU uses the 89C51 chip, and uses the 89C51P1 port to connect to two 8255 data buses, so there is no confusion of address and data; use the pins P20 and P21 of the 89C51P2 port to connect to the 8255 address lines A0 and A1 , 8255 chip select line (CS) is connected to P22, directly connected to 8255 through the software read and write control line, as long as the MOVX instruction is used in the software, it can be changed; the 3 I/O ports of 8255 have a total of 24 bits of data An external drive circuit is connected to control the sound and light alarm.

To sum up, the metallurgical hoisting machinery operation safety airborne early warning system provided by the present invention realizes the operation parameters such as the lifting weight, lifting height/falling depth, and operating stroke of the metallurgical hoisting machinery, the state of the brake of the hoisting mechanism, the door Real-time monitoring and early warning of working status such as limit, vibration of reducer, bearing temperature and other parameters, and real-time recording and data viewing of various operating parameters, working status, operation instructions, alarm conditions, etc., to prevent or eliminate causes Operational safety problems caused by faults. It solves the current problems in the operation safety of metallurgical cranes, improves the operation safety monitoring level of metallurgical cranes, thereby ensuring the safe operation of the cranes and reducing the occurrence of major accidents.

The above is only a preferred embodiment of the present invention, it should be pointed out that, for those of ordinary skill in the art, without departing from the principle of the present invention, some improvements and modifications can also be made, and these improvements and modifications can also be made. It should be regarded as the protection scope of the present invention.

Claims (10)

1. A metallurgical hoisting machinery operation safety airborne early warning system, is characterized in that, comprises: data acquisition layer, data transmission layer and industrial computer; Described industrial computer comprises data acquisition interface, data monitoring module and early warning module; Wherein, the data collection layer is used to collect the operation safety parameters of the monitored metallurgical hoisting machinery, and transmits to the data collection interface of the industrial computer through the data transmission layer; the data monitoring module is used to monitor the data collection The parameters received by the interface; the early warning module is used to analyze the parameters received by the data collection interface and give an early warning. 2. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 1, wherein the data acquisition layer includes a sensing layer and a signal processor; The sensing layer includes a PLC controller, a vibration sensor and a temperature sensor; wherein, the PLC controller is a controller configured by the monitored metallurgical hoisting machinery itself; the vibration sensor is used to collect the vibration signal of the reducer; the The temperature sensor is used to collect the temperature signal of the reducer; The signal processor is used to collect the output signal of the PLC controller, and is transmitted to the data acquisition interface of the industrial computer through the data transmission layer; the signal processor is also used for the speed reducer output by the temperature sensor The temperature signal is filtered, adjusted and converted from analog to digital, and then sent to the data acquisition interface of the industrial computer; the signal processor is also used to filter, adjust and modulo the vibration signal of the reducer output by the vibration sensor. conversion processing, and then send to the data acquisition interface of the industrial computer. 3. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 2, characterized in that the vibration sensor is a piezoelectric acceleration sensor, which is equipped with a charge amplifier itself, and its power supply and signal output share a common Shaft cable; it has a magnetic suction seat, and the vibration sensor is installed on the reducer box at the shaft end of the metallurgical hoisting machinery reducer through the magnetic suction seat. 4. The airborne early warning system for metallurgical hoisting machinery operation safety according to claim 2, wherein the temperature sensor is a platinum resistance temperature sensor PT100, which is installed on the reducer box at the shaft end of the reducer through a threaded connection superior. 5. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 2, wherein the signal processor collects the parameters output by the temperature sensor and the vibration sensor by the following method: The signal processor creates a device object handle for absolute control of a certain controlled device; The signal processor sets a sampling parameter corresponding to each sampling channel, and the sampling parameter includes a sampling frequency and a sensor type corresponding to the sampling channel; The signal processor reads the analog data transmitted by a certain sampling channel according to the sampling frequency, and then performs analog-to-digital conversion on the analog data to realize continuous and uninterrupted cyclic sampling; When it is necessary to read the data transmitted by other sampling channels, modify the sampling channel and sampling frequency parameters, and repeat the above cyclic sampling process; When it is necessary to stop sampling, release the device object handle. 6. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 2, wherein the signal processor collects the PLC controller output signal by the following method: The signal processor creates a device object handle for absolute control of a certain controlled device; wherein, the controlled device is equipped with a PLC controller; Initialize the sampling channel between the signal processor and the PLC controller; The signal processor directly reads the parameters stored inside the PLC controller. 7. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 2, wherein the PLC controller output signal includes: monitoring parameters and monitoring status; The monitoring parameters include: main lifting/auxiliary lifting/auxiliary lifting weight, lifting height, working time and corresponding operating instructions, the operating instructions include lifting instructions, stop instructions or lowering instructions; The monitoring parameters also include the running stroke of the cart/main trolley/auxiliary trolley, safety distance and corresponding operating instructions, which include left-moving instructions, right-moving instructions and stop instructions; The monitoring state includes the braking state of the main lift/auxiliary lift/auxiliary lift, the door limit interlock protection state and the inter-mechanism operation interlock protection state; among them, the main lift/auxiliary lift/auxiliary The braking state of hoisting is the state of whether the brake is open or not; The working time counts the start action time, end action time and working time period of the main hoist/auxiliary hoist/auxiliary hoist/truck/main trolley/auxiliary trolley. 8. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 1, wherein the data monitoring module includes a data display submodule, a data storage submodule and a data playback submodule; The data display sub-module is used to display the operation safety parameters of the metallurgical hoisting machinery in real time, and is also used to display the safety status of the monitored metallurgical hoisting machinery; the data storage sub-module is used to classify and store the corresponding The operation safety parameters; the data playback sub-module is used to call the operation safety history data of any historical time. 9. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 1, wherein the early warning module includes a threshold setting submodule and an overrun alarm submodule; The threshold setting submodule is used to set the operation safety limit value of each monitoring parameter; The overrun alarm sub-module is used to issue an alarm when the received monitoring parameter exceeds a corresponding threshold. 10. The metallurgical hoisting machinery operation safety airborne early warning system according to claim 9, characterized in that, the overrun alarm sub-module includes a control circuit and several drive circuits; the control circuit is used to communicate with the industrial control When the monitoring value received by the industrial computer exceeds the preset threshold, it sends a driving signal to the control circuit; when the control circuit receives the driving signal, it drives the corresponding driving circuit to give an audible and visual alarm.