CN109292633A - Crane structure stress real-time monitoring and fault diagnosis system based on technology of Internet of things - Google Patents
Crane structure stress real-time monitoring and fault diagnosis system based on technology of Internet of things Download PDFInfo
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- CN109292633A CN109292633A CN201811139953.0A CN201811139953A CN109292633A CN 109292633 A CN109292633 A CN 109292633A CN 201811139953 A CN201811139953 A CN 201811139953A CN 109292633 A CN109292633 A CN 109292633A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 28
- 238000005516 engineering process Methods 0.000 title claims abstract description 23
- 238000003745 diagnosis Methods 0.000 title claims abstract description 19
- 238000012545 processing Methods 0.000 claims abstract description 44
- 239000011888 foil Substances 0.000 claims abstract description 25
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 13
- 238000010276 construction Methods 0.000 claims abstract description 13
- 239000010959 steel Substances 0.000 claims abstract description 13
- 238000007619 statistical method Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 21
- QVFWZNCVPCJQOP-UHFFFAOYSA-N chloralodol Chemical compound CC(O)(C)CC(C)OC(O)C(Cl)(Cl)Cl QVFWZNCVPCJQOP-UHFFFAOYSA-N 0.000 claims description 10
- 238000003466 welding Methods 0.000 claims description 9
- 238000004364 calculation method Methods 0.000 claims description 6
- 238000010223 real-time analysis Methods 0.000 claims description 6
- 239000003292 glue Substances 0.000 claims description 4
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 3
- 230000005540 biological transmission Effects 0.000 claims description 3
- 230000015572 biosynthetic process Effects 0.000 claims description 3
- 238000004422 calculation algorithm Methods 0.000 claims description 3
- 239000010962 carbon steel Substances 0.000 claims description 3
- 230000001186 cumulative effect Effects 0.000 claims description 3
- 230000007423 decrease Effects 0.000 claims description 3
- 230000005764 inhibitory process Effects 0.000 claims description 3
- 238000002955 isolation Methods 0.000 claims description 3
- 230000001681 protective effect Effects 0.000 claims description 3
- 230000000630 rising effect Effects 0.000 claims description 3
- 238000004458 analytical method Methods 0.000 abstract description 6
- 230000007774 longterm Effects 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 5
- 230000002035 prolonged effect Effects 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000011105 stabilization Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000003321 amplification Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000007405 data analysis Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 230000004807 localization Effects 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 238000003199 nucleic acid amplification method Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
- B66C15/06—Arrangements or use of warning devices
- B66C15/065—Arrangements or use of warning devices electrical
Abstract
Crane structure stress real-time monitoring and fault diagnosis system based on technology of Internet of things, belong to special safety equipment monitoring technology field.Include foil gauge, signal condition and acquisition unit, local processing unit, cloud platform server；Foil gauge reflects the stress variation of testee by the deformation of steel construction, and signal condition and acquisition unit handle stress signal, and the stress data being calculated is transmitted to local processing unit；Local processing unit be used for by stress data it is for statistical analysis, be locally displayed in module and show at it；Cloud platform server is analyzed data and obtains real-time stress and show as a result, sending data to local processing unit in real time for receiving stress data.The present invention can long term monitoring stress, go to scene without personnel；It can be inquired at any time on cloud platform server, check analysis result；Acquisition mode is flexible, can select wirelessly or non-wirelessly mode according to on-site actual situations；The data such as stress course, fault message, fatigue life can be checked by cloud.
Description
Technical field
The invention belongs to special safety equipment monitoring technology field, in particular to a kind of crane based on technology of Internet of things
Structural stress real-time monitoring and fault diagnosis system.
Background technique
Currently, stress data can only lead at the scene in crane structure stress monitoring both domestic and external and malfunction analysis procedure
It crosses dedicated stress Acquisition Instrument and carries out data sampling and processing, display, and after acquisition is completed, could be counted on computers
Analyzed according to processing, that there are time spans is long, data processing is cumbersome, can not long-range real time inspection the problems such as.
Summary of the invention
In order to overcome problems of the prior art, the present invention provides a kind of crane structure based on technology of Internet of things
Stress real-time monitoring and fault diagnosis system.
The present invention adopts the technical scheme that achieve the above object: the crane structure stress based on technology of Internet of things is real
When monitoring and fault diagnosis system, it is characterised in that: this system include foil gauge, signal condition and acquisition unit, processing locality
Unit, cloud platform server；Foil gauge reflects the stress variation of testee by the deformation of steel construction, and strain gauge adhesion exists
On steel construction, outside is covered with one layer of waterproof and dustproof protective film, signal condition and acquisition unit and carries out the stress signal of foil gauge
Protection, filtering, acquires amplification, after the stress data being calculated by formula, is transmitted to local processing unit；
Stress data calculation formula:
σ=E × ε
σ --- stress, units MPa
E --- elasticity modulus, units MPa
ε --- strain, dimensionless
Local processing unit be used for by stress data it is for statistical analysis, be locally displayed in module at it and show stress data
And figure；Cloud platform server is analyzed data and obtains real-time stress and show as a result, sending number in real time for receiving stress data
According to arrive local processing unit.
The local processing unit includes connected with lower module:
Real time analysis module: by the real-time analysis of stress data, by observing whether stress data is in normal work
In range, judge that crane structure with the presence or absence of fault message, judging result is transmitted to, module is locally displayed；
Module is locally displayed: the stress data of crane exceeds normal range of operation, and it is aobvious that alarm will be carried out in cloud platform
Show.
Whether the stress data is in the judgement in normal range of operation, and common yield limit is less than
The carbon steel of 800MPa, when crane steady operation, the algorithm whether range of stress monitored is in normal range (NR) is as follows,
Unit of stress is MPa:
A) normal: -800≤σ≤800
B) improper: σ < -800 or σ > 800
C) improper: stress at any time substantially shaking always by course, | Δ σ | > 100, crane do not work or
When being hung load stabilization, stress course can not also be stablized
D) improper: when crane works, stress course never changes or amplitude of variation very little, | Δ σ | < 5
E) improper: when crane does not work, stable rising or the decline always of stress course；
When there is non-normal working, then judges that crane structure or stress acquisition unit break down, alarm
Prompt, while warning message being dealt into cloud platform.
The foil gauge is pasted on steel construction using welded type foil gauge or using special glue, and foil gauge can be adopted
Ji1/4Qiao or half-bridge or full bridge formation, to be applied to different steel construction regions.
The stress data Ethernet being calculated by formula or LORA wireless transmission method to local processing unit,
Local processing unit is connect with the connection of signal condition and acquisition unit using cable or LORA
It is wirelessly connected.
The cable connection type use surpasses five class double shield cables and connect with local processing unit, and radio connection is adopted
With the LORA chip APC340 of 433MHZ frequency, communicating unobstructed distance is 500 meters；
The ethernet module model USR-K3,10/100Mbps, MDI/MDIX intersect direct-connected automatic switchover, 1.5KV
Electromagnetic isolation supports IP, TCP, UDP, DHCP, DNS, HTTP, ARP network protocol.
Stress data is shown according to its corresponding time history curve, is stored by the local processing unit, complete by 4G
The GPRS module or WIFI of Netcom module SIM7600CE, the data such as stress course, warning message are sent to and are arranged in cloud
The privately owned cloud platform of each public cloud or self-built server can be used in cloud platform server, cloud platform server.
The cloud platform server counts stress data, by rain flow method using nominal stress method, hot spot
Stress method is based on S-N curve and Miner cumulative damage theory, calculates the fatigue damage of crane structure, cloud platform clothes
Warning message is led to the GPRS module or WIFI of module SIM7600CE by business device by 4G the whole network, sends data to processing locality list
Member synchronizes warning note by module is locally displayed；Cloud platform server further includes that may browse through live real time data, history
The module of data and curves, and including parameter can be arranged according to the actual situation on site, generate the module of corresponding data report.
The Fatigue Damage Calculation of the crane structure:
A) it is more than 10 plate thickness or more far from welding line structure or apart from welding line structure when monitoring point, then uses nominal stress
Method；
B) close or just in welded joints apart from welding line structure when monitoring point, then use hot spot stress method.
It is connected between the signal condition and acquisition unit and foil gauge using shielded cable, signal condition and acquisition unit
Using 16 ADC chip AD7705, sample frequency 10HZ-5kHZ；Signal condition and acquisition unit can acquire the strain of 4 tunnels simultaneously
Piece signal, linearity 0.1%FS, common mode inhibition (CMR) are not less than 100dB, system bandwidth: DC~500HZ, and strain full scale value ±
Noise: 3000 μ ε, ± 30000 μ ε are not more than 5 μ V, time drift: 3 μ of < V/ hours, temperature drift: 1 μ V/ DEG C of <.
The invention has the following advantages:
1, using modularization stress data modular design techniques, the acquisition of stress data, processing module are answered by original
Miscellaneous and expensive dedicated stress acquires equipment, is designed to small size, expansible stress acquisition module, by welded type or
Foil gauge is permanently affixed in structure to be detected, acquires strain data in real time by special glue, realizes prolonged stress number
According to acquisition.
2, using permanent type structural stress test macro, existing localization acquisition, ex-post analysis is changed into and adopted in real time
Collection, on-line analysis, can be real-time by the data platform of Internet of Things due to the provision of prolonged stress test data
Failure diagnosis information is provided, the advantage of Internet of Things has been played.
3, using technology of Internet of things, stress data acquisition, processing analysis is combined with Internet of Things, play the digging of big data
Potentiality are dug, intelligence carries out big data analysis with stress data, and it can trace at any time, carry out processing analysis according to function combination,
Data-handling capacity at least improves 10 times.
4, wireless+wired two kinds of connection types are used between signal condition and acquisition unit module, can be adapted for not
Same crane structure is being facilitated the place of arrangement cable to be arranged using cable, can adopted in the place for being inconvenient to arrange cable
With LORA wireless communication module.
Detailed description of the invention
Fig. 1 is system architecture schematic diagram of the invention.
Fig. 2 is signal condition of the present invention and acquisition unit block diagram.
Fig. 3 is signal condition of the present invention and acquisition unit circuit diagram.
Fig. 4 is signal condition of the present invention and acquisition unit and local processing unit circuit diagram.
Fig. 5 is signal condition of the present invention and acquisition unit, local processing unit and cloud platform connection schematic diagram.
Specific embodiment
Below in conjunction with attached drawing, the present invention is further described with embodiment:
Embodiment 1
As shown in Figure 1, crane structure stress real-time monitoring and fault diagnosis system based on technology of Internet of things, this system
Include foil gauge, signal condition and acquisition unit, local processing unit, cloud platform server；The shape that foil gauge passes through steel construction
The stress variation for becoming to reflect testee, for strain gauge adhesion on steel construction, outside is covered with one layer of waterproof and dustproof protective film,
The stress signal of foil gauge is protected, is amplified, is filtered, is acquired by signal condition and acquisition unit, is calculated by formula
Stress data after, be transmitted to local processing unit；
Stress data calculation formula:
σ=E × ε
σ --- stress, units MPa
E --- elasticity modulus, units MPa
ε --- strain, dimensionless
Local processing unit be used for by stress data it is for statistical analysis, be locally displayed in module at it and show stress data
And figure；Cloud platform server is analyzed data and obtains real-time stress and show as a result, sending number in real time for receiving stress data
According to arrive local processing unit.
The local processing unit includes connected with lower module:
Real time analysis module: by the real-time analysis of stress data, by observing whether stress data is in normal work
In range, judge that crane structure with the presence or absence of fault message, judging result is transmitted to, module is locally displayed；
Module is locally displayed: the stress data of crane exceeds normal range of operation, and it is aobvious that alarm will be carried out in cloud platform
Show.
Whether the stress data is in the judgement in normal range of operation, and common yield limit is less than
The carbon steel of 800MPa, when crane steady operation, the algorithm whether range of stress monitored is in normal range (NR) is as follows,
Unit of stress is MPa:
A) normal: -800≤σ≤800
B) improper: σ < -800 or σ > 800
C) improper: stress at any time substantially shaking always by course, | Δ σ | > 100, crane do not work or
When being hung load stabilization, stress course can not also be stablized
D) improper: when crane works, stress course never changes or amplitude of variation very little, | Δ σ | < 5
E) improper: when crane does not work, stable rising or the decline always of stress course；
When there is non-normal working, then judges that crane structure or stress acquisition unit break down, alarm
Prompt, while warning message being dealt into cloud platform.
The foil gauge is pasted on steel construction using welded type foil gauge or using special glue, and foil gauge can be adopted
Ji1/4Qiao or half-bridge or full bridge formation, to be applied to different steel construction regions.
The stress data Ethernet being calculated by formula or LORA wireless transmission method to local processing unit,
Local processing unit is connect with the connection of signal condition and acquisition unit using cable.
The cable connection type use surpasses five class double shield cables and connect with local processing unit；The ethernet module
Model USR-K3,10/100Mbps, MDI/MDIX intersect direct-connected automatic switchover, and 1.5KV electromagnetic isolation supports IP, TCP,
UDP, DHCP, DNS, HTTP, ARP network protocol.The local processing unit is by stress data according to its corresponding time history
Curve shows, stores, and the GPRS module or WIFI of module SIM7600CE is led to by 4G the whole network, by stress course, warning message etc.
Data are sent to the cloud platform server for being arranged in cloud, and each public cloud or self-built server can be used in cloud platform server
Privately owned cloud platform.
The cloud platform server counts stress data, by rain flow method using nominal stress method, hot spot
Stress method is based on S-N curve and Miner cumulative damage theory, calculates the fatigue damage of crane structure, cloud platform clothes
Warning message is led to the GPRS module or WIFI of module SIM7600CE by business device by 4G the whole network, sends data to processing locality list
Member synchronizes warning note by module is locally displayed；Cloud platform server further includes that may browse through live real time data, history
The module of data and curves, and including parameter can be arranged according to the actual situation on site, generate the module of corresponding data report.Institute
State the Fatigue Damage Calculation of crane structure:
A) it is more than 10 plate thickness or more far from welding line structure or apart from welding line structure when monitoring point, then uses nominal stress
Method；
B) close or just in welded joints apart from welding line structure when monitoring point, then use hot spot stress method.
It is connected between the signal condition and acquisition unit and foil gauge using shielded cable, signal condition and acquisition unit
Using 16 ADC chip AD7705, sample frequency 10HZ-5kHZ；Signal condition and acquisition unit can acquire the strain of 4 tunnels simultaneously
Piece signal, linearity 0.1%FS, common mode inhibition (CMR) are not less than 100dB, system bandwidth: DC~500HZ, and strain full scale value ±
Noise: 3000 μ ε, ± 30000 μ ε are not more than 5 μ V, time drift: 3 μ of < V/ hours, temperature drift: 1 μ V/ DEG C of <.
Embodiment 2
Crane structure stress described in the present embodiment based on the crane of technology of Internet of things based on technology of Internet of things is real
When monitoring and fault diagnosis system Each part and connection relationship technical parameter in the same manner as in Example 1, different are as follows:
1) connection of local processing unit and signal condition and acquisition unit is wirelessly connected using Ethernet or LORA；
2) radio connection uses the LORA chip APC340 of 433MHZ frequency, and communicating unobstructed distance is 500 meters；
3) stress data is shown according to its corresponding time history curve, is stored by the local processing unit, passes through 4G
Or the data such as stress course, warning message are sent to the cloud platform server for being arranged in cloud by WIFI；
4) the cloud platform server sends data to local processing unit by warning message by 4G or WIFI.
Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention., rather than its limitations；To the greatest extent
Pipe present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that: its according to
So be possible to modify the technical solutions described in the foregoing embodiments, or to some or all of the technical features into
Row equivalent replacement；And these are modified or replaceed, various embodiments of the present invention technology that it does not separate the essence of the corresponding technical solution
The range of scheme.
Claims (10)
1. crane structure stress real-time monitoring and fault diagnosis system based on technology of Internet of things, it is characterised in that: this system
Include foil gauge, signal condition and acquisition unit, local processing unit, cloud platform server；The shape that foil gauge passes through steel construction
The stress variation for becoming to reflect testee, for strain gauge adhesion on steel construction, outside is covered with one layer of waterproof and dustproof protective film,
The stress signal of foil gauge is protected, is amplified, is filtered, is acquired by signal condition and acquisition unit, is calculated by formula
Stress data after, be transmitted to local processing unit；
Stress data calculation formula:
σ=E × ε
σ --- stress, units MPa
E --- elasticity modulus, units MPa
ε --- strain, dimensionless
Local processing unit be used for by stress data it is for statistical analysis, show stress data and figure on its display module；
Cloud platform server is analyzed data and obtains real-time stress and show as a result, sending data in real time for receiving stress data
Ground processing unit.
2. according to claim 1 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: the local processing unit includes connected with lower module:
Real time analysis module: by the real-time analysis of stress data, by observing whether stress data is in normal range of operation
It is interior, judge that judging result with the presence or absence of fault message, is transmitted to alarm display module by crane structure；
Alarm display module: the stress data of crane exceeds normal range of operation, will be in local display and in cloud platform
Carry out alarm indication.
3. according to claim 2 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: whether the stress data is in the judgement in normal range of operation, common yield limit is less than
The carbon steel of 800MPa, when crane steady operation, the algorithm whether range of stress monitored is in normal range (NR) is as follows,
Unit of stress is MPa:
A) normal: -800≤σ≤800
B) improper: σ < -800 or σ > 800
C) improper: stress at any time substantially shaking always by course, | Δ σ | > 100, crane are not worked or have been hung
When carrying stable, stress course can not also be stablized
D) improper: when crane works, stress course never changes or amplitude of variation very little, | Δ σ | < 5
E) improper: when crane does not work, stable rising or the decline always of stress course；
When there is non-normal working, then judges that crane structure or stress acquisition unit break down, carries out warning note,
Warning message is dealt into cloud platform simultaneously.
4. according to claim 1 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: the foil gauge is pasted on steel construction using welded type foil gauge or using special glue, foil gauge can
To acquire 1/4 bridge or half-bridge or full bridge formation, to be applied to different steel construction regions.
5. according to claim 1 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: the stress data Ethernet being calculated by formula or LORA wireless transmission method are to processing locality list
Member, local processing unit is connect with the connection of signal condition and acquisition unit using cable or LORA is wirelessly connected.
6. according to claim 5 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: the cable connection type use surpasses five class double shield cables and connect with local processing unit, wireless connection side
Formula uses the LORA chip APC340 of 433MHZ frequency, and communicating unobstructed distance is 500 meters；The ethernet module model
USR-K3,10/100Mbps, MDI/MDIX intersect direct-connected automatic switchover, and 1.5KV electromagnetic isolation supports IP, TCP, UDP, DHCP,
DNS, HTTP, ARP network protocol.
7. according to claim 1 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: stress data is shown according to its corresponding time history curve, stored by the local processing unit, pass through 4G
The whole network leads to the GPRS module or WIFI of module SIM7600CE, and the data such as stress course, warning message are sent to and are arranged in cloud
Cloud platform server, the privately owned cloud platform of each public cloud or self-built server can be used in cloud platform server.
8. according to claim 1 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: the cloud platform server by rain flow method, counts stress data, using nominal stress method,
Hot spot stress method is based on S-N curve and Miner cumulative damage theory, calculates the fatigue damage of crane structure, Yun Ping
Warning message is led to the GPRS module or WIFI of module SIM7600CE by platform server by 4G the whole network, is sent data to and is originally located in
Unit is managed, synchronizes warning note by module is locally displayed；Cloud platform server further include may browse through live real time data,
The module of historical data curve, and including parameter can be arranged according to the actual situation on site, generate the mould of corresponding data report
Block.
9. according to claim 7 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: the Fatigue Damage Calculation of the crane structure:
A) it is more than 10 plate thickness or more far from welding line structure or apart from welding line structure when monitoring point, then uses nominal stress method；
B) close or just in welded joints apart from welding line structure when monitoring point, then use hot spot stress method.
10. according to claim 1 be based on technology of Internet of things crane structure stress real-time monitoring and fault diagnosis system,
It is characterized by: being connected between the signal condition and acquisition unit and foil gauge using shielded cable, signal condition and acquisition
Unit uses 16 ADC chip AD7705, sample frequency 10HZ-5kHZ；Signal condition and acquisition unit can acquire 4 tunnels simultaneously
Foil gauge signal, linearity 0.1%FS, common mode inhibition (CMR) are not less than 100dB, system bandwidth, and: DC~500HZ strains full scale
It is worth ± 3000 μ ε, ± 30000 μ ε, noise: is not more than 5 μ V, time drift: 3 μ of < V/ hours, temperature drift: 1 μ V/ DEG C of <.
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| CN110039218A (en) * | 2019-04-12 | 2019-07-23 | 中国大唐集团科学技术研究院有限公司火力发电技术研究院 | A kind of regulating units welding point stress test system |
| CN111782706A (en) * | 2020-06-09 | 2020-10-16 | 清华大学 | Jitter-free real-time rain flow counting method for structural fatigue life analysis |
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Application publication date: 20190201 |