CN111158307A - Tower crane fault diagnosis system - Google Patents
Tower crane fault diagnosis system Download PDFInfo
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- CN111158307A CN111158307A CN202010064269.1A CN202010064269A CN111158307A CN 111158307 A CN111158307 A CN 111158307A CN 202010064269 A CN202010064269 A CN 202010064269A CN 111158307 A CN111158307 A CN 111158307A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/058—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/14—Plc safety
- G05B2219/14045—Parameter, over or under condition detection
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Abstract
The invention provides a tower crane fault diagnosis system which comprises a PC (personal computer) controller, a PLC (programmable logic controller), a cloud server, an operating condition information acquisition sensor and a tower crane operation information acquisition sensor, wherein the operating condition information acquisition sensor and the tower crane operation information acquisition sensor are connected with the PLC controller; meanwhile, a model corresponding to the tower crane is built in the cloud server; when the system works, the cloud server inputs the working condition information parameters into the corresponding tower crane model for simulation, obtains the corresponding simulation operation parameters, judges the working state of the tower crane through comparison of the simulation operation parameters and the actual operation parameters, and sends the corresponding diagnosis results to the PC terminal and the operators of the specific PLC controller, so that the real-time monitoring of the working state of the tower crane is realized, the difficulty of tower crane fault judgment is reduced, and the efficiency of fault judgment is improved.
Description
Technical Field
The invention relates to the technical field of crane diagnosis equipment, in particular to a tower crane fault diagnosis system.
Background
The tower crane is the most common hoisting equipment on a construction site, is also called as a tower crane, and mainly plays a role in hoisting construction raw materials such as reinforcing steel bars, wood ridges, concrete, steel pipes and the like, so that the building materials are rapidly transported into a building, and the tower crane is indispensable equipment on the construction site. In the prior art, in order to improve the safety and the work efficiency of the tower crane, various intelligent sensors are continuously arranged on the tower crane, the safety and the work efficiency of the tower crane are continuously improved, along with the continuous increase of equipment, the maintenance in the later period causes great pressure, the manual detection and fault diagnosis mode in the prior art cannot adapt to the maintenance, and therefore the improvement of the fault diagnosis efficiency of the tower crane is the key for improving the work efficiency of the tower crane.
Disclosure of Invention
The invention discloses a tower crane fault diagnosis system, aiming at the defects of difficulty in tower crane fault diagnosis and low fault judgment efficiency in the prior art.
The invention realizes the aim through the following technical scheme:
a tower crane fault diagnosis system comprises a PC controller, a PLC controller, a cloud server, a working condition information acquisition sensor for acquiring working condition information parameters and a tower crane operation information acquisition sensor for acquiring actual operation parameters of a tower crane, wherein the working condition information acquisition sensor and the tower crane operation information acquisition sensor are both connected with a signal input end of the PLC controller, a signal output end of the PLC controller is in communication connection with the cloud server through a wireless communication module, and the PC controller is in communication connection with the cloud server through a TCP/IP protocol;
the cloud server is internally provided with a tower crane model, the working condition information parameters received to the PLC are input into the tower crane model to simulate the motion process, simulated operation parameters are generated, the cloud server compares the actual operation parameters with the simulated operation parameters and outputs corresponding diagnosis results to the PC controller and the specific PLC.
Preferably, the working condition information acquisition sensor comprises a wind speed sensor, a temperature sensor, a tension sensor, a speed sensor and a rotation angle sensor; the tower crane operation information acquisition sensor comprises an engine oil pressure sensor, an engine oil temperature sensor, a current and voltage sensor, a motor rotating speed sensor and an inclination angle sensor.
Preferably, the PC controller is also internally provided with a data storage module and a USB data transmission interface.
Preferably, the fault diagnosis system further comprises a touch display screen arranged in the cab of the tower crane, and the touch display screen is in communication connection with the PLC through a 485 bus communication technology.
Preferably, the diagnostic system further comprises an audible and visual alarm device, and the audible and visual alarm device is in communication connection with the PLC.
Preferably, the parameters transmitted to the PC controller by the PLC controller further include identification parameters corresponding to the tower cranes one to one, and the identification parameters are bound to corresponding working condition information parameters and actual operating parameters.
Preferably, the wireless communication module is a GPRS wireless communication module.
Compared with the prior art, the invention has the following beneficial effects:
1. the system comprises a PC controller, a PLC controller, a cloud server, a working condition information acquisition sensor and a tower crane operation information acquisition sensor, wherein the working condition information acquisition sensor and the tower crane operation information acquisition sensor are connected with the PLC controller; meanwhile, a model corresponding to the tower crane is built in the cloud server; when the system works, the cloud server inputs the working condition information parameters received in real time into the corresponding tower crane model for simulation, obtains corresponding tower crane simulation operation parameters, judges the working state of the tower crane through comparison of the simulation operation parameters and the actual operation parameters, and sends corresponding diagnosis results to the PC terminal and operators of the specific PLC controller, so that the real-time monitoring of the working state of the tower crane is realized, the difficulty of tower crane fault judgment is reduced, and the fault judgment efficiency is improved; the invention realizes the prejudgment before the tower crane fault occurs, and provides convenience for later-stage maintenance; the diagnostic system can also monitor the state of each component, is convenient for workers to quickly replace components close to the service life, and simplifies the daily maintenance work of the tower crane.
3. The PC controller is also internally provided with a data storage module and a USB data transmission interface, and a controller can download various tower crane operation data stored in the cloud server through the PC controller and realize data transmission through the USB interface, so that the analysis of later-stage faults is facilitated, the further improvement and analysis of the structural problems of the tower crane are facilitated, and the convenience is provided for the research and improvement work of the tower crane; technicians can further optimize the tower crane model according to the data, so that the running accuracy of the model is improved.
4. The fault diagnosis system also comprises a touch display screen arranged in the cab of the tower crane, wherein the touch display screen is in communication connection with the PLC through a 485 bus communication technology, so that an operator in the tower crane can conveniently and quickly know the working state of the tower crane, misoperation is avoided, and meanwhile, quick early warning and elimination can be realized for small problems, and the safe operation of the tower crane is ensured.
5. The diagnosis system also comprises an acousto-optic alarm device which is in communication connection with the PLC controller, so that the rapid alarm of major faults is realized, the attention of operators is aroused, and the safe operation of the tower crane is ensured.
6. The parameters transmitted to the PC controller by the PLC controller also comprise identification parameters which are in one-to-one correspondence with the tower cranes, and the identification parameters are bound with corresponding working condition information parameters and actual operation parameters, so that the correspondence between the tower cranes and the simulation model is ensured, and the synchronous monitoring and diagnosis of a plurality of tower cranes are realized.
Drawings
FIG. 1 is a schematic diagram of the inventive structure;
FIG. 2 is a flow chart of the present invention;
reference numerals: 1. PC controller, 2, PLC controller, 3, cloud ware, 4, operating mode information acquisition sensor, 5, tower machine operation information acquisition sensor, 6, wireless communication module, 7, data storage module, 8, USB data transfer interface, 9, touch-control display screen, 10, audible and visual alarm device
Detailed Description
The present invention will be further described with reference to the following description and examples, which include but are not limited to the following embodiments.
Embodiment mode 1
The embodiment is used as a basic embodiment of the invention and discloses a tower crane fault diagnosis system, which has a specific structure as shown in fig. 1 and fig. 2, and comprises a PC (personal computer) controller 1, a PLC (programmable logic controller) 2, a cloud server 3, a working condition information acquisition sensor 4 for acquiring working condition information parameters and a tower crane operation information acquisition sensor 4 for acquiring actual operation parameters of a tower crane, wherein the working condition information acquisition sensor 3 comprises a wind speed sensor and a temperature sensor for detecting the environment where the tower crane is located, a tension sensor for detecting the weight of a heavy object lifted by the tower crane, a speed sensor for detecting the lifting speed of a lifting hook and a corner sensor for detecting the corner of the tower crane, and simultaneously, data which have great influence on the service life of the tower crane can be acquired through a humidity sensor, a salinity sensor and the like according to; the tower crane operation information acquisition sensor 5 comprises an engine oil pressure sensor, an engine oil temperature sensor, a current voltage sensor, a motor rotating speed sensor, an inclination angle sensor and the like, wherein the sensors are uniformly distributed on each key node of the tower crane according to the actual condition of the tower crane so as to ensure the accuracy of detection data;
the signal input end of the PLC 2 is respectively connected with the working condition information acquisition sensor 4 and the tower crane operation information acquisition sensor 5, the output end of the PLC 2 is in communication connection with the cloud server 3 through a wireless communication module 6, and the wireless communication module 6 adopts a GPRS communication module; the PC controller 1 controls the cloud server 3 through a TCP/IP protocol;
a tower crane model is arranged in the cloud server 3, and is compiled by combining simulation software according to data such as actual size parameters, strength structure parameters and actual performance parameters of a tower crane structure provided by a manufacturer, and then is corrected in a later period by combining actual operation data; the acquisition position of the simulation parameters is the same as the setting position of the actual sensor, so that the authenticity and the comparability of data are ensured; the difference between the simulated operation parameters and the actual operation parameters comprises measurement errors of the measurement equipment and normal allowable errors; the cloud server runs the corresponding tower crane model through the working condition information parameters, obtains the corresponding tower crane simulation operation parameters, determines whether the working state of the tower crane is in a normal working range or not by comparing the simulation operation parameters with the actual operation parameters, and transmits the corresponding result to the PC controller 1 and the PLC controller 2 corresponding to the tower crane, so that an operator can conveniently observe the working state of the tower crane, and meanwhile, the operator can carry out various analysis operations on the cloud server 3 through the PC controller 1.
Embodiment mode 2
The embodiment is a preferred embodiment of the invention, and discloses a fault diagnosis system for a tower crane, which has a specific structure shown in fig. 1 and fig. 2, and comprises a PC controller 1, a PLC controller 2, a cloud server 3, a working condition information acquisition sensor 4 for acquiring working condition information parameters, and a tower crane operation information acquisition sensor 5 for acquiring actual operation parameters of the tower crane, wherein the PC controller 1 is internally provided with a data storage module 7 and a USB data transmission interface 8, so that data stored in the cloud server 3 is downloaded and stored;
further, the fault diagnosis system also comprises a touch display screen 9 arranged in the cab of the tower crane, wherein the touch display screen 9 is in communication connection with the PLC 2 through a 485 bus communication technology, and meanwhile, the output end of the PLC 2 is also connected with an audible and visual alarm device 10; when the PLC 2 sends the relevant parameters to the cloud server 3 through the wireless communication module, the pre-built identification parameters corresponding to the tower cranes are synchronously sent, so that the binding of the identification parameters, the working condition information parameters and the actual operation parameters is realized, and the real-time monitoring of the plurality of tower cranes is realized.
When the invention is used, the working condition information acquisition sensor acquires key data such as wind speed, temperature, mass lifting and the like of the environment where the tower crane is positioned, acquires key operation parameters such as motor rotating speed, voltage and current numerical values, oil temperature and machine pressure of a hydraulic system, load of each key acceptance part of the tower crane, inclination angle of the tower crane and the like in the operation process of the tower crane, transmits the working condition information parameters and the actual operation parameters to the cloud server through the PLC and the wireless communication module, the cloud server inputs the working condition information parameters into the corresponding tower crane model, obtains simulated operation parameters which are in one-to-one correspondence with each item of the actual operation parameters through the simulated operation of the tower crane, and contrasts and analyzes the simulated operation parameters and the actual operation parameters by combining the difference values such as measurement errors, component allowable errors and the like, thereby diagnosing the working condition of the tower crane according to the abnormal change condition of, the diagnosis result is sent to the PC controller and the corresponding PLC controller, so that the tower crane is monitored by workers, and the fault point is quickly pre-judged and maintained, the efficiency of confirming the tower crane fault is greatly improved, and the maintenance difficulty is reduced; meanwhile, the invention can also find out the parts at the end of the service life by comparing and analyzing the parameters, thereby maintaining the equipment before the accident happens, avoiding the frequent occurrence of the fault and ensuring the continuous and stable work of the tower crane; the real-time monitoring data of the tower crane can be used for continuously updating and perfecting a tower crane model, so that the diagnosis accuracy is improved, and meanwhile, the tower crane can be further improved, so that data support is provided for maintenance of the tower crane.
Claims (7)
1. The utility model provides a tower machine fault diagnosis system, includes PC controller (1), PLC controller (2), cloud server (3), its characterized in that: the system is characterized by further comprising a working condition information acquisition sensor (4) for acquiring working condition information parameters and a tower crane operation information acquisition sensor (5) for acquiring actual operation parameters of the tower crane, wherein the working condition information acquisition sensor (4) and the tower crane operation information acquisition sensor (5) are both connected with a signal input end of the PLC (2), a signal output end of the PLC (2) is in communication connection with the cloud server (3) through a wireless communication module (6), and the PC controller (1) is in communication connection with the cloud server (3) through a TCP/IP protocol;
the cloud server (3) is internally provided with a tower crane model, the working condition information parameters received to the PLC (programmable logic controller) (2) are input into the tower crane model to simulate the motion process, simulated operation parameters are generated, the cloud server (3) compares the actual operation parameters with the simulated operation parameters, and corresponding diagnosis results are output to the PC (1) and the specific PLC (2).
2. The tower crane fault diagnosis system according to claim 1, characterized in that: the working condition information acquisition sensor (4) comprises a wind speed sensor, a surrounding environment temperature sensor, a lifting hook tension sensor, a lifting speed sensor and a corner sensor; the tower crane operation information acquisition sensor (5) comprises an engine oil pressure sensor, an engine oil temperature sensor, a current voltage sensor, a motor rotating speed sensor and an inclination angle sensor.
3. The tower crane fault diagnosis system according to claim 1, characterized in that: the PC controller (1) is also internally provided with a data storage module (7) and a USB data transmission interface (8).
4. The tower crane fault diagnosis system according to claim 1, characterized in that: the fault diagnosis system further comprises a touch display screen (9) arranged in the tower crane cab, and the touch display screen (9) is in communication connection with the PLC (programmable logic controller) controller (2) through a 485 bus communication technology.
5. The tower crane fault diagnosis system according to claim 1, characterized in that: the diagnosis system also comprises an acousto-optic alarm device (10), and the acousto-optic alarm device (10) is in communication connection with the PLC (2).
6. The tower crane fault diagnosis system according to claim 1, characterized in that: the parameters transmitted to the cloud server (3) by the PLC (2) further comprise identification parameters bound with the tower cranes one by one, and the identification parameters are bound with corresponding working condition information parameters and actual operation parameters.
7. The tower crane fault diagnosis system according to claim 1, characterized in that: the wireless communication module (6) adopts a GPRS wireless communication module.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010064269.1A CN111158307A (en) | 2020-01-20 | 2020-01-20 | Tower crane fault diagnosis system |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010064269.1A CN111158307A (en) | 2020-01-20 | 2020-01-20 | Tower crane fault diagnosis system |
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| CN111158307A true CN111158307A (en) | 2020-05-15 |
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| CN202010064269.1A Pending CN111158307A (en) | 2020-01-20 | 2020-01-20 | Tower crane fault diagnosis system |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111994797A (en) * | 2020-09-10 | 2020-11-27 | 徐工消防安全装备有限公司 | Safety control method and system for aerial work platform |
| CN112881005A (en) * | 2021-03-23 | 2021-06-01 | 普沃思环保科技无锡有限公司 | Rotating wheel data acquisition method, device, equipment and storage medium |
| CN113219927A (en) * | 2021-05-13 | 2021-08-06 | 南京联迪信息系统股份有限公司 | Industrial internet platform monitoring data transmission and exchange method and system |
| CN113996953A (en) * | 2020-07-28 | 2022-02-01 | 宝山钢铁股份有限公司 | Comprehensive state data acquisition and analysis system of laser welding machine |
| CN114348887A (en) * | 2022-03-21 | 2022-04-15 | 杭州杰牌传动科技有限公司 | Intelligent monitoring and early warning system and method based on tower crane rotation action model |
-
2020
- 2020-01-20 CN CN202010064269.1A patent/CN111158307A/en active Pending
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113996953A (en) * | 2020-07-28 | 2022-02-01 | 宝山钢铁股份有限公司 | Comprehensive state data acquisition and analysis system of laser welding machine |
| CN113996953B (en) * | 2020-07-28 | 2023-08-11 | 宝山钢铁股份有限公司 | State data comprehensive acquisition and analysis system of laser welder |
| CN111994797A (en) * | 2020-09-10 | 2020-11-27 | 徐工消防安全装备有限公司 | Safety control method and system for aerial work platform |
| CN112881005A (en) * | 2021-03-23 | 2021-06-01 | 普沃思环保科技无锡有限公司 | Rotating wheel data acquisition method, device, equipment and storage medium |
| CN113219927A (en) * | 2021-05-13 | 2021-08-06 | 南京联迪信息系统股份有限公司 | Industrial internet platform monitoring data transmission and exchange method and system |
| CN114348887A (en) * | 2022-03-21 | 2022-04-15 | 杭州杰牌传动科技有限公司 | Intelligent monitoring and early warning system and method based on tower crane rotation action model |
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