CN107966232B - Method and system for monitoring performance of hoisting equipment brake based on machine vision - Google Patents
Method and system for monitoring performance of hoisting equipment brake based on machine vision Download PDFInfo
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- CN107966232B CN107966232B CN201711188160.3A CN201711188160A CN107966232B CN 107966232 B CN107966232 B CN 107966232B CN 201711188160 A CN201711188160 A CN 201711188160A CN 107966232 B CN107966232 B CN 107966232B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/28—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for testing brakes
- G01L5/284—Measuring braking-time or braking distance
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
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Abstract
The invention aims to provide a method and a system for monitoring the performance of a brake of hoisting equipment, which comprises an image acquisition unit, an image processing and analyzing unit, a data storage module, a data communication module, a remote analysis and diagnosis center, a real-time display module, an audible and visual alarm module and a function key, and aims to solve the problem that the long-term real-time online monitoring and the predictive maintenance of the braking torque and the stroke of a pusher cannot be carried out in the prior art.
Description
Technical Field
The invention relates to the field of hoisting equipment performance monitoring, in particular to a method and a system for monitoring the performance of a hoisting equipment brake based on machine vision.
Background
The hoisting equipment is widely applied to various industries of national economy such as metallurgy, electric power, ports, logistics, mechanical manufacturing, building industry, ocean engineering and the like, and is important process equipment for industrial production. The lifting, amplitude variation, operation and rotation mechanisms of the power-driven crane are all provided with brakes. The electro-hydraulic brake is a standard series brake commonly used for hoisting equipment and mainly comprises an electro-hydraulic pusher and a brake frame. The electric hydraulic pusher consists of a driving motor and a body (centrifugal pump), and the body consists of a cover, a cylinder, a piston rod, a push rod sheath, an impeller and a rotating shaft. The brake frame mainly comprises brake shoe, brake arm, brake pull rod, lever, brake spring and other parts. The brake utilizes the friction principle to realize the braking of the mechanism. The friction part of the brake presses the brake wheel or brake disc in the mechanism with a certain acting force to generate a braking torque, and the braking torque is used to reduce the torque generated by the mass of the object and the inertia force until the two torques are balanced, thereby achieving the requirements of speed regulation or braking. The magnitude of the braking torque and the travel of the pusher directly reflect the performance of the brake. When the brake works, the braking torque is formed by two parts, one part is the braking torque generated by the pretightening force of the braking spring on the braking frame; the other part is the braking torque generated by the thrust of the electro-hydraulic thruster. The brake spring is arranged in the spring pipe, and a brake torque scale is arranged on one side of the spring pipe for installation and maintenance personnel to observe the magnitude of the brake torque so as to make corresponding adjustment. A stroke indicator scale is arranged beside a push rod sheath of the pusher, and the working stroke of the pusher is in a green range of the stroke indicator scale. The lower end of the push rod sheath is used in a state that the push rod sheath enters a red area of a stroke scale when the brake is closed, otherwise the brake can be out of order to cause serious accidents.
With the gradual maturity of modern automation industrial technology, performance monitoring of hoisting equipment brakes can not be completed through manual operation or the manual operation can not meet the requirements of industrial production due to various reasons such as production efficiency, human resource allocation, bad working environment and the like. In this case, it is necessary to use a machine vision system as a substitute for manual work. The machine vision technology converts an acquired object into an image signal through an image acquisition device and then transmits the image signal to an image processing system. Converting the image signal into a digital signal; and the image processing system extracts the target characteristics according to the obtained digital signals and judges the running state of the equipment.
At present, the pretightening force of a brake spring and the stroke of a pusher of a hoisting equipment brake are mainly detected by manually and visually detecting a brake torque scale so as to judge whether the pretightening force is in a safety range or not and whether the working stroke of the pusher is in a stroke scale range or not, but the manual detection has low efficiency and low speed and is influenced by the manual detection, the precision is general, the brake spring and the pusher are easy to fatigue, are influenced by emotion fluctuation, have limited working time, are not easy to integrate information and increase the labor and management cost, and are not suitable for severe. Because manual detection needs to be performed in a state that the hoisting equipment is stopped, the state of the brake cannot be dynamically monitored in real time. The other method is that a proximity switch and a mechanical limit switch are arranged on the pusher to detect the working state of the brake, and an electronic ruler is arranged on the pusher to detect the stroke of the pusher, but the proximity switch and the mechanical limit switch can only detect whether the brake is in an open or closed state, and cannot measure the stroke of the push rod. Although the electronic ruler can measure the stroke of the pusher, the electronic ruler is greatly influenced by environmental factors and has low precision. And no matter install proximity switch, mechanical limit switch or electronic ruler, all need drill on the impeller, to the in-service hoisting equipment who does not install stopper proximity switch, mechanical limit, electronic ruler when dispatching from the factory, if need install above detection device, owing to involve drilling processing, destroy the current structure of impeller, reduced the factor of safety of stopper to a certain extent, the installation degree of difficulty is great.
Disclosure of Invention
The invention provides a method and a system for monitoring the performance of a hoisting equipment brake based on machine vision, which aim to solve the problem that long-term real-time online monitoring and predictive maintenance on brake torque and pusher stroke cannot be carried out in the prior art.
The invention provides a hoisting equipment brake performance monitoring system based on machine vision, which comprises an image acquisition unit, an image processing and analyzing unit, a data storage module, a data communication module, a remote analysis and diagnosis center, a real-time display module, an audible and visual alarm module, a function key I and a function key II. The image acquisition unit is connected with the image processing and analyzing unit; the image processing and analyzing unit is connected with the real-time display module and the sound-light alarm module; the image processing and analyzing unit is connected with the data storage module; the data storage module is connected with the data communication module; the data communication module is connected with the remote analysis and diagnosis center.
Furthermore, the first function key can temporarily close the sound alarm function in the sound and light alarm; the second function key can control whether the system starts to store the image shot by the industrial camera.
Furthermore, the image acquisition unit comprises an industrial camera, a camera support, a light source support, an upright post, a sliding block and a mounting support, wherein the sliding block is arranged on the upright post of the mounting support, the camera support and the light source support are arranged on the sliding block, the industrial camera is arranged on the camera support, and the light source is arranged on the light source support.
Further, the mounting bracket is connected with the mounting position through threads or welded during mounting.
Furthermore, a sliding block on an upright post of the mounting bracket can be adjusted up and down and can be locked and fixed at any position of the upright post, a camera bracket mounted on the sliding block can be adjusted in angle and position and locked at any position, and a light source bracket mounted on the sliding block can be adjusted in angle and position.
A hoisting equipment brake performance monitoring system based on machine vision, a brake performance monitoring method thereof, comprises the following steps:
(1) the visual system acquisition setting comprises setting for light adjustment, light source adjustment and focal length adjustment;
(2) system software extracts characteristic images of a brake spring scale and a brake push rod travel scale;
(3) the system software tracks the action of the brake;
(4) carrying out error test to filter out interference data;
(5) setting an alarm threshold value according to the action of the brake;
(6) completing setting and entering a normal acquisition mode;
(7) the software measurement data changes along with the action of the brake;
(8) judging whether the set threshold value is exceeded or not by software;
(9) if the alarm value is exceeded, carrying out alarm prompt, and if no alarm exists, carrying out the next step;
(10) recording the data of each action travel;
(11) recording the action time and the action cycle period time of the brake;
(12) circulating to the step (7);
(13) extracting the characteristic value of the data at regular time;
(14) predicting a brake state trend;
(15) and (5) providing a maintenance plan and giving an early warning.
When the braking torque and the travel of the pusher reach dangerous values or the variation trend is gradually close to the dangerous values, an alarm signal is sent to a driver through a field instrument arranged in a cab to remind the driver to contact maintenance personnel to adjust the travel of the braking spring and the pusher. And meanwhile, the data after image processing is transmitted to a remote diagnosis and analysis center to analyze the data, and the law of the brake performance, the brake spring moment and the stroke change of the pusher is found out. And a maintenance strategy of braking spring moment and pusher stroke adjustment is given, and the subsequent maintenance is converted into advance prevention, so that the safe operation of the hoisting equipment is ensured to the maximum extent.
Drawings
FIG. 1 is a schematic structural diagram of an image acquisition unit;
FIG. 2 is a schematic view of a brake spring scale;
FIG. 3 is a schematic structural diagram of a brake push rod travel scale;
FIG. 4 is a flow chart of a brake performance monitoring method.
Detailed Description
The hoisting equipment brake performance monitoring system based on machine vision comprises an image acquisition unit, an image processing and analyzing unit, a data storage module, a data communication module, a remote analysis and diagnosis center, a real-time display module, an audible and visual alarm module, a function key I and a function key II.
As shown in fig. 1, the image acquisition unit comprises an industrial camera 3, a camera support 6, a light source 4, a light source support 5, an upright post 1, a slider 2 and a mounting support, wherein the slider 2 is arranged on the upright post of the mounting support, the camera support 6 and the light source support 5 are arranged on the slider 2, the industrial camera 3 is arranged on the camera support 6, and the light source 4 is arranged on the light source support 5.
Further, the mounting bracket is connected with the mounting position through threads or welded during mounting.
Furthermore, a sliding block on an upright post of the mounting bracket can be adjusted up and down and can be locked and fixed at any position of the upright post, a camera bracket mounted on the sliding block can be adjusted in angle and position and locked at any position, and a light source bracket mounted on the sliding block can be adjusted in angle and position.
Connecting an image acquisition unit with an image processing and analyzing unit; the image processing and analyzing unit is connected with the real-time display module and the sound-light alarm module; the image processing and analyzing unit is connected with the data storage module; the data storage module is connected with the data communication module; the data communication module is connected with the remote analysis and diagnosis center; the first function key can temporarily close the sound alarm function in the sound and light alarm; the second function key can control whether the system starts to store the image shot by the industrial camera.
The mounting bracket provided with the industrial camera 3 and the light source 4 is placed right in front of the brake spring ruler, the power supply of the industrial camera 3 and the power supply of the light source 4 are switched on, monitoring system software is operated, and images acquired by the industrial camera 3 are displayed on a display. The position of the mounting bracket is adjusted, the upper and lower positions of the sliding block 2 are adjusted, and the angles and the positions of the industrial camera 3 and the light source 4 are adjusted, so that the brake spring ruler is positioned in the visual field range of the lens of the industrial camera 3, and clear images of the ruler can be acquired. The brake spring scale is composed of a spring square tube 11, a spring scale 12, a brake spring 13 and an indication block 14, an alarm threshold value is set, and when the scale of the brake spring scale exceeds the threshold value set by the system, an alarm is triggered.
The mounting bracket provided with the industrial camera 3 and the light source 4 is placed right in front of the brake push rod stroke scale, the power supply of the industrial camera 3 and the power supply of the light source 4 are switched on, monitoring system software is operated, and images acquired by the industrial camera are displayed on a display. The position of the mounting bracket is adjusted, the upper position and the lower position of the sliding block 2 are adjusted, and the angles and the positions of the industrial camera 3 and the light source 4 are adjusted, so that the brake push rod stroke scale is positioned in the visual field range of the lens of the industrial camera 3, and clear images of the scale can be acquired. The brake push rod stroke scale is composed of a push rod sheath 7, a pusher cylinder cover 10 and a scale, wherein the scale is divided into a scale red area 9 and a scale green area 8.
After the hoisting equipment starts to be electrified and operated, the system software, the industrial camera 3 and the light source 4 start to work, the acquired images are transmitted to the image processing and analyzing unit in real time, and the processed images are displayed on a display located in a cab. When the scale of the brake spring scale exceeds the set threshold value of the system, the audible and visual alarm works to remind a driver to take corresponding measures. The system stores the acquired images into a data storage module periodically and in the working (opening and closing) stage of the brake and periodically transmits the images to a remote analysis and diagnosis center for analysis and diagnosis through a data communication module.
Claims (2)
1. The hoisting equipment brake performance monitoring system based on machine vision comprises an image acquisition unit, an image processing and analyzing unit, a data storage module, a data communication module, a remote analysis and diagnosis center, a real-time display module, an audible and visual alarm module, a function key I and a function key II; wherein the image acquisition unit is connected with the image processing and analyzing unit; the image processing and analyzing unit is connected with the real-time display module and the sound-light alarm module; the image processing and analyzing unit is connected with the data storage module; the data storage module is connected with the data communication module; the data communication module is connected with the remote analysis and diagnosis center; the first function key can temporarily close the sound alarm function in the sound and light alarm; the second function key can control whether the system starts to store the image shot by the industrial camera (3); the image acquisition unit comprises an industrial camera (3), a camera support (6), a light source (4), a light source support (5), an upright post (1), a sliding block (2) and a mounting support, wherein the sliding block (2) is arranged on the upright post (1) of the mounting support, the camera support (6) and the light source support (5) are respectively arranged on the sliding block (2), the sliding block (2) can be adjusted up and down and is locked and fixed at any position of the upright post (1), the camera support (6) arranged on the sliding block (2) can be adjusted in angle and position and is locked at any position, and the light source support (5) arranged on the sliding block (2) can be adjusted in angle and position; an industrial camera (3) is arranged on the camera support (6), a light source (4) is arranged on the light source support (5), the mounting support is placed in front of the brake spring scale, and the industrial camera (3) is used for collecting images of the brake spring scale; the brake spring scale is composed of a spring square tube (11), a spring scale (12), a brake spring (13) and a indicating value block (14), an alarm threshold value is set, and when the scale of the brake spring scale exceeds the alarm threshold value set by the system, an alarm is triggered.
2. A brake performance monitoring method applying the machine vision based lifting equipment brake performance monitoring system of claim 1, characterized by comprising the steps of:
(1) the visual system acquisition setting comprises setting for light adjustment, light source adjustment and focal length adjustment;
(2) system software extracts characteristic images of a brake spring scale and a brake push rod travel scale;
(3) the system software tracks the action of the brake;
(4) carrying out error test to filter out interference data;
(5) setting an alarm threshold value according to the action of the brake;
(6) completing setting and entering a normal acquisition mode;
(7) the software measurement data changes along with the action of the brake;
(8) judging whether the alarm threshold value is exceeded or not by software;
(9) if the alarm threshold value is exceeded, carrying out alarm prompting, and if no alarm exists, carrying out the next step;
(10) recording the data of each action stroke of the brake;
(11) recording the action time and the action cycle period time of the brake;
(12) circulating to the step (7);
(13) extracting the characteristic value of the data at regular time;
(14) predicting a brake state trend;
(15) and (5) providing a maintenance plan and giving an early warning.
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| CN201711188160.3A CN107966232B (en) | 2017-11-24 | 2017-11-24 | Method and system for monitoring performance of hoisting equipment brake based on machine vision |
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| CN201711188160.3A CN107966232B (en) | 2017-11-24 | 2017-11-24 | Method and system for monitoring performance of hoisting equipment brake based on machine vision |
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| CN107966232B true CN107966232B (en) | 2020-04-24 |
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Effective date of registration: 20211207 Address after: Room 710, block a, building 2, Xiyuan, Heping Street, Chaoyang District, Beijing 100020 Patentee after: BEIJING ZHONGJIAN HOPES TECHNOLOGY CO.,LTD. Address before: 100029 No.2 Xiyuan, Heping Street, Chaoyang District, Beijing Patentee before: CHINA SPECIAL EQUIPMENT INSPECTION AND Research Institute Patentee before: Beijing Zhongjian hope Technology Co., Ltd |
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Address after: Room 710, block a, building 2, Xiyuan, Heping Street, Chaoyang District, Beijing 100020 Patentee after: China Merchants zhongtezhi inspection (Beijing) Technology Co.,Ltd. Address before: Room 710, block a, building 2, Xiyuan, Heping Street, Chaoyang District, Beijing 100020 Patentee before: BEIJING ZHONGJIAN HOPES TECHNOLOGY CO.,LTD. |