CN111977514A - Preventive maintenance system of crane based on Internet of things - Google Patents
Preventive maintenance system of crane based on Internet of things Download PDFInfo
- Publication number
- CN111977514A CN111977514A CN202010948085.1A CN202010948085A CN111977514A CN 111977514 A CN111977514 A CN 111977514A CN 202010948085 A CN202010948085 A CN 202010948085A CN 111977514 A CN111977514 A CN 111977514A
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- things
- crane
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/40—Applications of devices for transmitting control pulses; Applications of remote control devices
- B66C13/44—Electrical transmitters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/48—Automatic control of crane drives for producing a single or repeated working cycle; Programme control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/50—Applications of limit circuits or of limit-switch arrangements
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- 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
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Automation & Control Theory (AREA)
- Control And Safety Of Cranes (AREA)
Abstract
The invention relates to a crane preventive maintenance system based on the Internet of things, which comprises a cloud server, an Internet of things module, a sensor module and a control module, wherein the cloud server, the Internet of things module, the control module and the sensor module are sequentially in signal connection, the sensor module comprises a weighing sensor, a space limit sensor, a heavy hammer limiter, an overload limiter, an anemoscope limiter, a cab door limiter and a phase sequence protector, the control module comprises a PLC (programmable logic controller) control unit and a remote I/0 communication unit, the remote I/0 communication unit is in communication connection with the PLC control unit, the remote I/0 communication unit acquires data information of the sensor module and transmits the data information to the PLC control unit, a crane national standard data model is embedded in the Internet of things module, the Internet of things module reads and counts the data information, compares the data information with the crane national standard data model to judge maintenance requirements and uploads the maintenance, and a data storage unit is arranged in the cloud server, so that the fault of the crane is predicted in advance, and the maintenance stroke is optimized conveniently.
Description
Technical Field
The invention belongs to the technical field of hoisting machinery, and particularly relates to a preventive maintenance system for a crane based on the Internet of things.
Background
The crane is used as hoisting and carrying equipment in factory workshops, tunnel bridge construction, buildings, port wharfs and other occasions, is very widely applied, and is necessary equipment for normal production in some factories, and the safety performance of the crane is also emphasized because the crane has great promotion effect on national economic development or enterprise production efficiency.
Disclosure of Invention
The invention aims to provide a crane preventive maintenance system based on the Internet of things, and the system can be used for solving the problem of predicting the fault of a crane so as to optimize the maintenance stroke.
In order to solve the problems, the invention adopts the technical scheme that:
a crane preventive maintenance system based on the Internet of things comprises a cloud server, an Internet of things module, a sensor module and a control module, wherein the cloud server, the Internet of things module, the control module and the sensor module are sequentially in signal connection, the sensor module comprises a weighing sensor, a space limiting sensor, a heavy hammer limiter, an overload limiter, an anemoscope limiter, a cab door limiter and a phase sequence protector, the control module comprises a PLC (programmable logic controller) control unit and a remote I/0 communication unit, the remote I/0 communication unit is in communication connection with the PLC control unit, the remote I/0 communication unit collects sensor module data information and transmits the sensor module data information to the PLC control unit, a crane national standard data model is embedded in the Internet of things module, and the Internet of things module reads and counts data information to compare the data information with the crane national standard data model to judge maintenance requirements and transmit the data information to the cloud server, and a data storage unit is arranged in the cloud server.
Furthermore, the device also comprises a driving module, the driving module is in communication connection with the PLC control unit, the driving module comprises a lifting unit, a trolley running unit and a cart running unit, the lifting unit, the trolley running unit and the cart running unit respectively comprise a frequency converter, a motor and a brake, the frequency converter respectively controls the motor and the brake to run, the PLC control unit controls the frequency converter to run, and the frequency converter outputs a brake control signal to control the brake to run.
Furthermore, anti-shaking control units are arranged in the frequency converters.
Furthermore, the remote control system also comprises a cab operation module, wherein the cab operation module is in signal connection with the remote I/0 communication unit, the cab operation module comprises a monitoring unit, an operation platform and a remote controller, the monitoring unit monitors the operation mode of a driver, the remote controller is in wireless communication connection with the operation platform, the remote I/0 communication unit acquires data information of the cab operation module and transmits the data information to the PLC control unit, and the PLC control unit receives the data information of the cab operation module and controls the operation of the driving module.
Furthermore, the intelligent control system also comprises an upper computer, wherein the upper computer is in signal connection with the control module, a storage unit and a display unit are arranged in the upper computer, historical data information is stored in the storage unit, and the display unit displays the data information in real time.
Further, the upper computer is an IT6070E touch screen.
Further, the cloud server further comprises an application terminal, wherein the application terminal comprises a mobile phone application terminal and a computer application terminal, and the mobile phone application terminal and the computer application terminal are respectively in signal connection with the cloud server.
Furthermore, the device also comprises an alarm module, and the alarm module is in signal connection with the PLC control unit.
By adopting the technical scheme, the invention has the beneficial effects that:
according to the invention, the functions of safety early warning, maintenance reminding, abnormal state and abnormal operation record archiving, key data statistical statement and the like are realized by monitoring the running state and the operation behavior of the equipment in real time, the fault of the crane is predicted in advance, the accident is reduced, the accident source tracing and the maintenance stroke optimization are facilitated, and the remote operation, maintenance and debugging of the crane can also be realized.
Drawings
FIG. 1 is a schematic diagram of the structural relationship of the present invention.
Reference numerals: 1. a cloud server; 11. a data storage unit; 2. a control module; 21. a PLC control unit; 22. a remote I/O communications unit; 3. a sensor module; 31. a weighing sensor; 32. a spatial limit sensor; 33. a weight limiter; 34. an overload limiter; 35. an anemometer stop; 36. a cab door check; 37. a phase sequence protector; 4. an Internet of things module; 41. a crane national standard data model; 5. a drive module; 51. a lifting unit; 52. a trolley running unit; 53. a cart running unit; 54. a frequency converter; 55. a motor; 56. a brake; 57. an anti-swing control unit; 6. an upper computer; 61. a storage unit; 62. a display unit; 7. a cab operation module; 71. a monitoring unit; 72. an operating platform; 73. a remote controller; 8. an application terminal; 81. a mobile phone application terminal; 82. a computer application terminal; 9. and an alarm module.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more clear, embodiments of the present invention are described in further detail below with reference to the accompanying drawings.
As shown in fig. 1, the invention provides a crane preventive maintenance system based on the internet of things, which comprises a cloud server 1, an internet of things module 4, a sensor module 3 and a control module 2, wherein the cloud server 1, the internet of things module 4, the control module 2 and the sensor module 3 are sequentially in signal connection, specifically, the control module 2 and the internet of things module 4 are in communication through ModbusTcp, the internet of things module 4 and the cloud server 1 are in communication through a virtual VPN channel, and the sensor module 3 comprises a weighing sensor 31 for measuring the weight of a crane lifting object; the space limit sensor 32 is used for controlling the limit of the left, right, up and down of each running mechanism of the crane; the weight limiter 33 is used for preventing the lifting hook or the grab bucket from impacting the top; an overload stop 34 for preventing the crane from running over load; the anemometer limiter 35 is used for measuring the ambient wind speed of the crane; a cab door checker 36 for controlling whether the crane is operating; and the phase sequence protector 37 is used for automatically judging the phase sequence of the power supply, and each component unit of the sensor module 3 can protect the operation safety of each operating mechanism of the crane.
The control module 2 comprises a PLC control unit 21 and a remote I/0 communication unit 22, the remote I/0 communication unit 22 is in communication connection with the PLC control unit 21, concretely, the PLC control unit 21 and the remote I/0 communication unit 22 are in communication in a CANlink bus mode, communication stability is guaranteed, at the moment, the remote I/0 communication unit 22 collects data information of the sensor module 3, the remote I/0 communication unit 22 collects the data information of the sensor module 3 and transmits the data information to the PLC control unit 21, a crane national standard data model 41 is embedded in the Internet of things module 4, the crane national standard data model 41 is a data model for storing data information such as total safe working time, maintenance period and total safe times of brakes of each mechanism of the crane, and the data information such as the total safe working time, the maintenance period and the total safe times of the brakes of each mechanism of the crane is mainly obtained by applying a statistical correlation method to the data information The method comprises the following steps of digging, carrying out data statistics modeling, predicting when the crane needs to be maintained and maintained by the Internet of things module 4 through a statistics method, and maintaining the crane in a preventive mode, namely, after the Internet of things module 4 reads and counts data information, comparing the data information with the crane national standard data model 41, judging and predicting maintenance requirements, and uploading the maintenance requirements to the cloud server 1, specifically, after the Internet of things module 4 reads and counts the data information, comparing the data information with a theoretical life value to obtain a coefficient, obtaining whether maintenance is needed or not through the value in the crane national standard data model 41 and the coefficient, arranging a data storage unit 11 in the cloud server 1, wherein the data storage unit 11 is used for storing the data information which is read and counted by the Internet of things module 4.
Further, the device also comprises a driving module 5, the driving module 5 is in communication connection with the PLC control unit 21, specifically, the PLC control unit 21 and the driving module 5 communicate with each other in a CANlink bus manner to ensure communication stability, the driving module 5 comprises a lifting unit 51, a trolley running unit 52 and a trolley running unit 53, the lifting unit 51, the trolley running unit 52 and the trolley running unit 53 all comprise a frequency converter 54, a motor 55 and a brake 56, the frequency converter 54 respectively controls the motor 55 and the brake 56 to run, the PLC control unit 21 controls the frequency converter 54 to run, specifically, the frequency converter 54 drives the lifting unit 51, the trolley running unit 53 and the motor 55 of the trolley running unit 52 to run, the frequency converter 54 mainly controls the motor 55, namely receives a running instruction and a speed instruction sent by the PLC control unit 21 to complete control of the motor 55, the frequency converter 54 also outputs a brake control signal to control the brake 56 to operate, the PLC control unit 21 can also collect the state information of the frequency converter 54, and the data information such as the crane operating current, the operating frequency, the hoisting weight, the situation of encountering the positive and negative limits in the operating process of the driving module 5 is received as the data for predictive maintenance, and the data information is transmitted to the internet of things module 4.
Further, the frequency converters 54 are all provided with anti-swing control units 57, and the anti-swing control units 57 are used for preventing swing during operation of the crane.
Further, the system also comprises a cab operation module 7, the cab operation module 7 is in signal connection with the remote I/0 communication unit 22, specifically, the cab operation module 7 is connected with the remote I/0 communication unit 22 through an I/O line, at this time, the remote I/0 communication unit 22 is used for completing data information acquisition of operation signals of the cab operation module 7, the cab operation module 7 comprises a monitoring unit 71, an operation platform 72 and a remote controller 73, the operation platform 72 mainly comprises a master controller and a button box, crane operation modes are divided into three operation modes of idle operation, ground operation and the remote controller, different control modes can be freely combined and combined according to actual requirements, the monitoring unit 71 monitors the operation modes of drivers, the operation states of traveling vehicles, the traveling speed and the like can be judged by monitoring the operations of the drivers, the remote controller 73 is in wireless communication connection with the operation platform 72, the remote I/0 communication unit 22 collects data information of the cab operation module 7 and transmits the data information to the PLC control unit 21, the crane operation mode is judged by the PLC control unit 21, in addition, the lifting, cart or trolley operation and the action direction of each mechanism can be known by reading input point signals of an I/O module of the operation platform 72, the PLC control unit 21 receives the data information of the cab operation module 7 and controls the driving module 5 to operate, concretely, the cab operation module 7 transmits control signals to the PLC control unit 21 to control the driving module 5 to operate, at the moment, the PLC control unit 21 is a master station, the cab operation module 7 and the driving module 5 are respectively slave stations, because the slave stations can not exchange information and can realize information exchange after being transmitted by the master station, in addition, the data processing can be realized by means of the logic operation function of the PLC to obtain the required data for control, meanwhile, the PLC control unit 21 compares and predicts the data information through the crane national standard data model 41 in the internet of things module 4, thereby implementing the preventive maintenance function.
The principle and preventive maintenance of the invention are explained in detail by combining the modules:
the principle of the system for realizing monitoring is that the IOT module 4 is firstly connected with an Internet network, such as a 4G card, wireless WIFI (wireless fidelity), a wired network and the like, then the IOT module 4 and the cloud server 1 establish a virtual VPN (virtual private network) channel, the PLC control unit 21 can be remotely connected through a Ukey dongle and a debugging assistant, and the PLC control unit 21, the sensor module 3 and the driving module 5 realize information interaction through bus communication, so that real-time remote monitoring is realized.
The preventive maintenance of the invention is that the Internet of things module 4 reads the running signals, limit signals, lifting weight, motor current, brake using times and the like of each mechanism of the crane, comprehensively analyzes data for a period of time to obtain the data such as the running time of the crane, the lifting overload times, the lifting load weight, the brake using condition, the limiting times when the crane is touched and the like, then the preventive maintenance of the crane is realized by comparing and predicting with the national standard data model 41 of the crane, the maintenance stroke is optimized, for example, the theoretical maintenance value of the brake using times is 5 times, when the Internet of things module 4 reads and counts the brake using times to reach 5 times, the brake is checked whether to be normally used continuously or not, so as to carry out the preventive maintenance, in addition, the reasons for the maintenance of the crane, such as whether the crane runs due to frequent overload or not, whether the crane is, Whether the driver violates the operation or not can be analyzed and traced.
Further, the intelligent monitoring system also comprises an upper computer 6, wherein the upper computer 6 is in signal connection with the control module 2, specifically, the upper computer 6 is in communication with the control module 2 through ModbusTcp, a storage unit 61 and a display unit 62 are arranged in the upper computer 6, historical data information is stored in the storage unit 61, the display unit 62 displays the data information in real time, specifically, the upper computer 6 is an IT60 6070E touch screen, and the upper computer 6 is used for monitoring the running state, fault information and speed setting of each mechanism of the driving module 5; historical fault information can be stored through the storage unit 61, and if a fault occurs, the fault tracing is facilitated; data information of the sensor module 3 and the drive module 5, such as weight information, operating frequency, a failure state of the drive module 5, a sensor ON/OFF state, and the like, can also be displayed in real time through the display unit 62, and further, the operation manner of the driver can also be displayed ON the IT6070E touch screen.
Further, the system also comprises an application terminal 8, the application terminal 8 comprises a mobile phone application terminal 81 and a computer application terminal 82, the mobile phone application terminal 81 and the computer application terminal 82 are respectively in signal connection with the cloud server 1, due to the wide application of the frequency converter 54 and the control module 2 on the crane, the on-site debugging can not meet the maintenance requirement of the crane gradually, especially in dangerous or on-site environment severe occasions, the debugging technicians are not convenient to go to the on-site debugging, and through setting the application terminal 8 to be in signal connection with the cloud server 1, the debugging personnel can remotely operate, maintain and debug the crane through the mobile phone application terminal 81 or the computer application terminal 82.
Further, the system also comprises an alarm module 9, wherein the alarm module 9 is in signal connection with the PLC control unit 21, and the alarm module 9 is used for realizing safety early warning and maintenance reminding when the running state of the crane reaches the predicted maintenance service life value.
Further, the actions of the present invention are summarized as follows:
information of the crane, such as running state, running time, fault information and the like, can be edited and processed through the internet of things module 4, the PLC control unit 21 and the remote I/0 communication unit 22, and the running state and data statistics of the equipment can be mastered in real time; remote operation, maintenance, debugging and remote parameter modification are carried out through the Internet of things module 4, the PLC control unit 21, the remote I/0 communication unit 22, the cloud server 1 and the application terminal 8; the alarm module 9 is used for reminding maintenance, so that the maintenance is accurate, and the service and working efficiency are improved; the system can be used for predicting the fault of the crane, recording the abnormal state and the abnormal operation whole process, and is convenient for tracing the accident; data information is subjected to statistical analysis and a statistical report is generated through the Internet of things module 4, and the operation state of the crane can be conveniently mastered.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are given by way of illustration of the principles of the present invention, and that various changes and modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is defined by the appended claims and equivalents.
Claims (8)
1. The utility model provides a hoist preventive maintenance system based on thing networking which characterized in that: the system comprises a cloud server (1), an Internet of things module (4), a sensor module (3) and a control module (2), wherein the cloud server (1), the Internet of things module (4), the control module (2) and the sensor module (3) are sequentially in signal connection, the sensor module (3) comprises a weighing sensor (31), a space limiting sensor (32), a heavy hammer limiter (33), an overload limiter (34), an anemoscope limiter (35), a cab door limiter (36) and a phase sequence protector (37), the control module (2) comprises a PLC control unit (21) and a remote I/0 communication unit (22), the remote I/0 communication unit (22) is in communication connection with the PLC control unit (21), and the remote I/0 communication unit (22) collects data information of the sensor module (3) and transmits the data information to the PLC control unit (21), thing networking module (4) are embedded to have hoist national standard data model (41), and thing networking module (4) read and statistical data information judges the maintenance demand and uploads to cloud ware (1) with its and hoist national standard data model (41) contrast, be provided with data storage unit (11) in cloud ware (1).
2. The Internet of things-based crane preventive maintenance system as claimed in claim 1, wherein: the device is characterized by further comprising a driving module (5), the driving module (5) is in communication connection with the PLC control unit (21), the driving module (5) comprises a lifting unit (51), a trolley running unit (52) and a cart running unit (53), the lifting unit (51), the trolley running unit (52) and the cart running unit (53) respectively comprise a frequency converter (54), a motor (55) and a brake (56), the frequency converter (54) respectively controls the motor (55) and the brake (56) to run, the PLC control unit (21) controls the frequency converter (54) to run, and the frequency converter (54) outputs a brake control signal to control the brake (56) to run.
3. The Internet of things-based crane preventive maintenance system as claimed in claim 2, wherein: and anti-shaking control units (57) are arranged in the frequency converters (54).
4. The Internet of things-based crane preventive maintenance system as claimed in claim 3, wherein: it still includes driver's cabin operation module (7), driver's cabin operation module (7) and long-range I/0 communication unit (22) signal connection, driver's cabin operation module (7) are including monitoring unit (71), operation platform (72) and remote controller (73), monitoring unit (71) control driver mode of operation, remote controller (73) and operation platform (72) wireless communication connection, long-range I/0 communication unit (22) gather driver's cabin operation module (7) data message and convey to PLC the control unit (21), PLC the control unit (21) receive driver's cabin operation module (7) data message and control drive module (5) operation.
5. The Internet of things-based crane preventive maintenance system as claimed in claim 4, wherein: the intelligent control system is characterized by further comprising an upper computer (6), wherein the upper computer (6) is in signal connection with the control module (2), a storage unit (61) and a display unit (62) are arranged in the upper computer (6), historical data information is stored in the storage unit (61), and the display unit (62) displays the data information in real time.
6. The Internet of things-based crane preventive maintenance system as claimed in claim 5, wherein: the upper computer (6) is an IT6070E touch screen.
7. The Internet of things-based crane preventive maintenance system as claimed in claim 5, wherein: the cloud server system is characterized by further comprising an application terminal (8), wherein the application terminal (8) comprises a mobile phone application terminal (81) and a computer application terminal (82), and the mobile phone application terminal (81) and the computer application terminal (82) are respectively in signal connection with the cloud server (1).
8. The Internet of things-based crane preventive maintenance system as claimed in claim 6, wherein: the intelligent alarm device also comprises an alarm module (9), wherein the alarm module (9) is in signal connection with the PLC control unit (21).
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010948085.1A CN111977514A (en) | 2020-09-10 | 2020-09-10 | Preventive maintenance system of crane based on Internet of things |
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| CN202010948085.1A CN111977514A (en) | 2020-09-10 | 2020-09-10 | Preventive maintenance system of crane based on Internet of things |
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