CN113125148B

CN113125148B - Portable closed gearbox detection device and abnormity determination method

Info

Publication number: CN113125148B
Application number: CN202010040285.7A
Authority: CN
Inventors: 朱列昂; 杨建华; 刘国强; 贺骏; 吴胜健; 顾宫磊
Original assignee: Baoshan Iron and Steel Co Ltd
Current assignee: Baoshan Iron and Steel Co Ltd
Priority date: 2020-01-15
Filing date: 2020-01-15
Publication date: 2023-03-14
Anticipated expiration: 2040-01-15
Also published as: CN113125148A

Abstract

The invention discloses a portable closed gearbox detection device and an abnormity judgment method, relates to the field of hoisting machinery, and is used for real-time monitoring of the running state of an inner gear of a gearbox in dynamic running of a crane and early warning control when the gear is abnormally deformed. The invention can make anyone check at any time without the help of related professional detection personnel, common point detection personnel can operate alone, the system has an intelligent judgment mechanism, can effectively judge the danger degree of related equipment, and is more intelligent and humanized.

Description

Portable closed gearbox detection device and abnormity judgment method

Technical Field

The invention relates to the field of hoisting machinery, in particular to a portable closed gearbox detection device and an abnormity judgment method, which are used for real-time monitoring of the running state of a gear in a gearbox in dynamic running of a crane and early warning control when the gear is abnormally deformed.

Background

Any moving mechanism (including a translation mechanism and a hoisting mechanism) in the hoisting machinery has basically the same structure and belongs to an electromechanical integrated product. Taking a translational motion mechanism as an example, a fast shaft led out by a motor is connected with a reduction gearbox (also called a gearbox) through a brake to change torque, drive a slow shaft and be connected with a corresponding driving wheel to enable the slow shaft to run. The speed reduction box has the functions of reducing the rotating speed and increasing the torque. The speed reducer is an important transmission part of the bridge crane, transmits torque through gear engagement, adjusts the high-speed running of the motor to the required rotating speed, and is composed of a plurality of groups of different gears, mainly comprising an input shaft, a sun gear, a planet gear shaft, a planet carrier, an inner gear ring, a connector, a bearing, a sealing element and the like. In addition, lubricating grease is required to be filled in the reduction gearbox body, so that corresponding parts such as the gear set, the bearing and the like are fully soaked in the lubricating grease, and the effect of reducing friction is achieved. Thus, the reduction gearbox is a sealed device. When the speed reducer operates, mechanical faults such as gear tooth breakage, tooth surface pitting, tooth surface gluing, tooth surface abrasion and the like can occur in the process of transmitting torque by the gear.

Because the reduction gearbox is a sealed device, when detecting and detecting the flaw in the reduction gearbox, inspectors cannot visually observe the states of the gear set and the bearing in the reduction gearbox, and the detection is very inconvenient. The detection method used at present is to use a special infrared detector and a atlas instrument to combine exploration, to hire related professionals, and to perform periodic flaw detection by multiple persons, generally 2-4 times per year, and to invest a great deal of detection cost per year. And the gear caused by inconvenient detection cannot be timely and effectively overhauled and replaced when abnormal, the safety condition of the reduction gearbox cannot be ensured by periodic inspection, the effect is not ideal, and considerable potential safety hazards are brought.

In actual production, because the crane is mobile and stops frequently, and the dynamic operation is very high to the wearing and tearing of reducing gear box internals under the state of long-term high strength load, and because the reducing gear box is the characteristics of closing device and brings very big inconvenience for some personnel of examining when examining, and can't accomplish the state of each part in the real time monitoring reducing gear box, when reducing gear box internal gear or bearing appear the fracture, can take place the serious consequence of the unusual pulsation of hoist during operation, even more will cause the reducing gear box because the friction produces the burning, and depend on the oil and form the occurence of failure of major fire.

Disclosure of Invention

Technical problem to be solved

The invention provides a portable closed gearbox detection device and an abnormity judgment method aiming at the defect problems in the prior art, through the collection and comparison of vibration waves during the dynamic operation of a crane, if abnormal deviation exists, a point inspection person is warned, so that the point inspection person can confirm the state of a related reduction gearbox at the position where the abnormal sound occurs, and the crane accident caused by the gear breakage or the abnormity of bearing cracking, breakage and the like is avoided.

(II) technical scheme

The utility model provides a portable closed gear box detection device, including the detection instrument, the record appearance, the computer terminal, install vibration wave collector and wireless communication module on the detection instrument, the vibration wave signal that vibration wave collector on the detection instrument gathered passes through wireless communication module wireless transmission for the record appearance, the record appearance links to each other with the computer terminal, the computer terminal is through the normal interval section of shielding vibration wave, judge whether have the wavelength that surpasss the normal wavelength interval, if so carry out intelligent judgement according to different danger grades, show red, yellow, green three kinds of signal lamps and carry out corresponding feedback.

According to an embodiment of the present invention, the wireless communication module is a Zigbee wireless module or a bluetooth module.

According to one embodiment of the invention, the detecting instrument comprises a wireless transmission module, an exhaust hole, a sensor, a vibration wave collector, a rubber gasket, a small air pump and an isolation cover; the wireless transmission module is arranged at the top of the detector; the side wall around the detector is provided with an isolation cover, the upper part of the isolation cover is provided with an exhaust hole, and the exhaust hole is connected with a small-sized air pump; the bottom of the detecting instrument is provided with a rubber gasket; and a vibration wave collector is arranged in the detecting instrument, and a sensor is arranged on the vibration wave collector.

According to an embodiment of the present invention, the isolation cover is tempered glass.

According to an embodiment of the present invention, the vibration wave collector is a metal bar, and the sensor is installed in the middle of the metal bar to collect the vibration waves.

A portable closed gearbox abnormity discrimination method comprises the following steps:

s1, mounting a portable detector on a reduction gearbox, starting a power supply, enabling an air suction pump to work to discharge air in an isolation hood housing, enabling a vibration wave collector to be in an internal vacuum state, and enabling the detector to operate;

s2, when the speed reducer acts, the vibration wave collector collects vibration signals and transmits the vibration signals to the recorder through the wireless transmission module;

s3, judging a wavelength band signal by a microcomputer: h < E < H?

Wherein E is a collected wavelength signal section, H to H wavelength signals are normal signal sections, and when the normal wavelength signals exceeding H to H appear, the interior of the speed reducer is abnormal;

s4, the microcomputer enters an intelligent judgment stage, the judgment level is set to be 3, the abnormal danger level can be automatically judged according to the wavelength signals in different level ranges and the motion frequency, and different abnormal signal lamps are lightened according to different levels;

and S5, intelligently judging the three levels to prompt detection personnel to perform tracking and deep maintenance in different degrees, timely finding and processing before serious threat to safety production occurs, and replacing a damaged gear or bearing to ensure normal operation of the speed reducer.

According to an embodiment of the present invention, in step S4, a green light is lit within the wavelength range of level 1, which is a light threat and indicates that there may be some wear of internal gears or bearings, and further observation is subsequently required, and if a more serious threat level occurs after a later period of use, disassembly and maintenance are required.

According to an embodiment of the present invention, in step S4, a yellow light is turned on in the 2 nd order wavelength range, which is a moderate threat and indicates that the internal gear or bearing has been damaged to some extent.

According to an embodiment of the invention, in the step S4, the red light is lighted within the wavelength range of the level 3, which is a serious threat, and indicates that the internal structure of the reduction gearbox has been seriously damaged, and the reduction gearbox needs to be shut down and overhauled in time.

(III) advantageous effects

By adopting the portable closed gearbox detection device and the abnormity determination method, the problem that the crane reduction gearbox is abnormal can be effectively solved in actual production according to the fact that the existing large-scale hoisting equipment monitors the crane closed type speed reducer at any time in a less-people and unmanned state, the hoisting safety operation rate is improved, abnormal accidents are prevented, the safety of production logistics is effectively controlled, and the effect of solving the production safety problem is achieved; the invention can make anyone check at any time without the help of related professional detection personnel, common point detection personnel can operate alone, the system has an intelligent judgment mechanism, can effectively judge the danger degree of related equipment, and is more intelligent and humanized.

Drawings

In the present invention, like reference numerals refer to like features throughout, wherein:

FIG. 1 is a schematic block diagram of the apparatus of the present invention;

FIG. 2 is a view showing the structure of the detector;

FIG. 3 is a graph of vibration wavelength versus time;

FIG. 4 is a range wavelength processing curve;

fig. 5 is a flowchart of an abnormality determination method of the present invention.

Description of reference numerals:

1. a detector; 2. a recorder; 3. a microcomputer terminal; 11. a wireless transmission module; 12. an exhaust hole; 13. a sensor; 14. a vibration wave collector; 15. a rubber gasket; 16. a small air pump; 17. and (7) an isolation cover.

Detailed Description

The technical scheme of the invention is further explained by combining the drawings and the embodiment.

The reasons for causing the fault of the gear in the reduction gearbox of the crane are as follows: 1) Fatigue fracture caused by short-time overload or impact load and repeated bending for many times; 2) The tooth surface is not smooth, and stress concentration is generated by convex points; 3) Lubrication failure due to excessive temperature; 4) Wear is caused by hard particles entering the friction surface. The crane speed reducer can cause a certain degree of abrasion problem due to long-time and continuous operation, or cause dust particles to enter the reduction gearbox to cause abrasion to the gear for a long time due to careless installation and maintenance. Under the influence of the factors, the normal and safe operation of the bridge crane is seriously influenced by the conditions that the gear set and the bearing in the running reduction gearbox of the crane gradually crack or even break and the like. The present invention utilizes the vibration wave produced by gear set and bearing during operation, and the vibration wave is collected, filtered and compared and analyzed automatically by microcomputer. Because irregular vibration is generated when the gear or the bearing in the reduction gearbox is subjected to abnormal change, abnormal vibration waves can be collected and judged by the detector, so that the condition that the components in the reduction gearbox are abnormal is determined. The device realizes timely discovery, timely early warning and timely maintenance, and ensures that the speed reducer runs in a safe and stable state.

Referring to fig. 1, a portable closed gearbox detection device, including detection instrument 1, record appearance 2, computer terminal 3, install vibration wave collector and wireless communication module 11 on detection instrument 1, the vibration wave signal that vibration wave collector on detection instrument 1 gathered passes through wireless communication module 11 wireless transmission for record appearance 2, record appearance 2 links to each other with computer terminal 3, computer terminal 3 judges whether there is the wavelength that surpasses normal wavelength interval through the normal interval section of shielding vibration wave, if so carry out intelligent judgement according to different danger grades, show red, yellow, green three kinds of signal lamps and carry out corresponding feedback.

The wireless communication module 11 may be a Zigbee wireless module or a bluetooth module.

Referring to fig. 2, the detecting instrument 1 includes a wireless transmission module 11, an exhaust hole 12, a sensor 13, a vibration wave collector 14, a rubber gasket 15, a small-sized air pump 16, and an isolation cover 17. The side wall all around of detection instrument 1 is equipped with cage 17, and the bottom of detection instrument 1 is installed rubber packing ring 15, and wireless transmission module 11 is installed at the top of detection instrument 1, and the upper portion of detection instrument 1 is seted up exhaust hole 12, and exhaust hole 12 links to each other with small-size aspiration pump 16, and the internally mounted of detection instrument 1 shakes ripples collector 14, installs sensor 15 on shaking ripples collector 14.

The isolation cover is made of reinforced glass and is provided with an exhaust hole, air in the cover is pumped out by using a small-sized air pump, and a relatively vacuum environment is manufactured to isolate external sound and vibration.

The vibration wave collector is a metal bar, the sensor is arranged in the middle of the metal bar and used for collecting vibration waves, and the collected vibration wave signals are transmitted to the recorder by the wireless transmission module.

In conjunction with fig. 3, the vibration wave is an elastic wave radiating from the vibration source. The broken gears and bearings will generate abnormal fluctuation which can be interpreted as a vibration source, and the center of the disturbance constitutes a wave source because the vibration source will be propagated and moved radially through different media (air, lubricating oil, metal shells and the like). This wave propagates from the inside to the outside and to the surface layer, forming a vibration wave in the continuous medium. The shell is made to the ripples collector that shakes utilizes tempered glass, and the air pump of integral type will cover is taken out from to obtain a relative vacuum state, because the vacuum passes the material for non-, shielded external disturbance as far as, the ripples signal that shakes that the sensor that makes in the metal rod was collected is more accurate.

Fig. 4 is a sectional wavelength processing curve, the signal collected from the recorder is an uninterrupted continuous wavelength signal, and the front section part shows no wavelength because the reduction gearbox is in a stop state. The generation of the wavelength signal means that the crane is in a running state (the running work of the speed reducer), the vibration wave collector collects the wavelength signal, the microcomputer removes the normal wavelength signal in the red line through automatic identification, and when the abnormal vibration wavelength is detected, intelligent identification is carried out according to the abnormal grade to prompt the abnormality of the equipment.

With reference to fig. 5, a method for judging abnormality of a portable enclosed gearbox includes the following steps:

s1, mounting a portable detector on a reduction gearbox and starting a power supply to enable an air suction pump to work to discharge air in a shield shell of an isolation hood, so that a vibration wave collector is in an internal vacuum state, and the detector operates;

s3, judging wavelength band signals by a microcomputer: h < E < H?

Wherein, E is the collected wavelength signal section, H to H wavelength signals are normal signal sections (which can be set by a microcomputer according to the previously collected related normal data), and when the normal wavelength signals exceeding H to H appear, the inside of the speed reducer may be abnormal.

And S4, the microcomputer enters an intelligent judgment stage, the judgment level is set to be 3, the abnormal danger level can be automatically judged according to the wavelength signals in different level ranges and the motion frequency, and different abnormal signal lamps are lightened according to different levels.

The green light is lighted within the wavelength range of 1 grade, which belongs to mild threat and indicates that certain abrasion of internal gears or bearings is possible, and further observation is needed subsequently, and if a more serious threat level appears after the light-emitting diode is used for a later period, the light-emitting diode needs to be disassembled for maintenance.

The yellow light is lighted in the 2-level wavelength range, which belongs to a moderate threat and indicates that the internal gear or the bearing has certain damage, and the stage is the product tracked according to the previous judgment.

The red light is lighted within the range of 3-level wavelength, which belongs to serious threat and indicates that the internal structure of the reduction gearbox has serious destructive damage and needs to be stopped and overhauled in time, and the generation of the wave band is caused by the condition that the reduction gearbox is damaged destructively or acutely, which is also the most serious condition.

And S5, intelligently judging the three levels to prompt detection personnel to track and deeply maintain in different degrees, and timely finding and processing the damaged gear or bearing before serious threat to safety production (accident), so that the normal operation of the speed reducer is ensured.

The first embodiment is as follows:

in the routine inspection, the detection instrument detects the reduction gearbox of the crane, the crane operates after the air pump is used for discharging redundant air, and the gear set in the reduction gearbox operates. The detector detects that the vibration wavelength in the reduction gearbox is between 'H < E < H', so that the normal state is fed back.

Example two:

in daily inspection, a detector is used for detecting a reduction gearbox of the crane, after redundant air is exhausted by using an air pump, the crane operates, and a gear set in the reduction gearbox operates. The detector detects that the vibration wavelength E in the reduction gearbox exceeds a set range value 'H < E < H', and judges that the wavelength E is in a grade 1 mild range, the recorder starts to record the detection time and state, and a green signal lamp is lighted on a microcomputer terminal to warn a detector that the reduction gearbox needs to be tracked and checked.

Example three:

in daily inspection, a detector is used for detecting a reduction gearbox of the crane, after redundant air is exhausted by using an air pump, the crane operates, and a gear set in the reduction gearbox operates. The detector detects that the vibration wavelength E in the reduction gearbox exceeds a set range value 'H < E < H', judges that the wavelength E exceeds a 3-level range, the recorder starts to record the detection time and state, a red signal lamp is lighted on a microcomputer terminal, and an alarm is given to a detector to stop running the reduction gearbox immediately, replace parts and overhaul.

In order to check the running state of the closed speed reducer of the crane and overcome the defects that the speed reducer is difficult to check and cannot be visually detected, the vibration wave collector is used for collecting the vibration waves generated by the speed reducer in the running process, and the vibration wave collector is used for processing and judging according to the vibration waves, so that the crane closed speed reducer helps inspectors to effectively monitor the state of the speed reducer of the crane. The invention is convenient, effective and reasonable, is convenient for personnel to carry, is designed to be portable and convenient to carry, only needs to place the collector on the reduction gearbox for the detection personnel to automatically operate, and immediately obtains a feedback result after the collection of a small segment of periodic wave length. The invention can carry out the inspection operation by common personnel without the trouble of assisting and using a plurality of large-scale detection devices by a plurality of people originally involved in the inspection, thereby greatly saving the labor cost and the additional expenditure. In view of the possible failure of the sensors in the metal bar, 2 sensors were installed, and the probe could continue to be used in the event of failure of one of the sensors.

In conclusion, by adopting the technical scheme of the invention, the portable closed gearbox detection device and the abnormity judgment method, the crane closed speed reducer is monitored at any time under the unmanned and unmanned states of the existing large-scale hoisting equipment, the problem of abnormity of the crane speed reducer can be effectively solved in actual production, the hoisting safety operation rate is improved, abnormal accidents are prevented, the safety of production logistics is effectively controlled, and the effect of solving the production safety problem is achieved; the invention can make anyone check at any time without the help of related professional detection personnel, common point detection personnel can operate alone, the system has an intelligent judgment mechanism, can effectively judge the danger degree of related equipment, and is more intelligent and humanized.

Claims

1. A portable enclosed gearbox detection device characterized in that: the system comprises a detecting instrument, a recorder and a microcomputer terminal, wherein the detecting instrument is provided with a vibration wave collector and a wireless communication module, vibration wave signals collected by the vibration wave collector on the detecting instrument are wirelessly transmitted to the recorder through the wireless communication module, the recorder is connected with the microcomputer terminal, the microcomputer terminal judges whether wavelengths exceeding a normal wavelength range exist or not by shielding a normal interval of vibration waves, if yes, intelligent judgment is carried out according to different danger grades, three signal lamps of red, yellow and green are displayed for corresponding feedback,

the detecting instrument comprises a wireless transmission module, an exhaust hole, a sensor, a vibration wave collector, a rubber gasket, a small air pump and an isolation cover;

the wireless transmission module is arranged at the top of the detector;

the side wall around the detector is provided with an isolation cover, the upper part of the isolation cover is provided with an exhaust hole, and the exhaust hole is connected with a small-sized air pump;

a rubber gasket is arranged at the bottom of the detector;

a vibration wave collector is arranged in the detecting instrument of the detecting instrument, and a sensor is arranged on the vibration wave collector;

the vibration wave collector is a metal bar, and the sensor is arranged in the middle of the metal bar and used for collecting vibration waves.

2. The portable enclosed gearbox detection device of claim 1, wherein the wireless communication module is a Zigbee wireless module or a bluetooth module.

3. A portable enclosed gearbox detection device as defined in claim 1, wherein said shield is tempered glass.

4. A portable closed gearbox abnormity discrimination method is characterized by comprising the following steps:

s3, judging wavelength band signals by a microcomputer: h < E < H?

5. The portable closed gearbox abnormality distinguishing method according to claim 4, wherein in the step S4, a green light is lighted in a wavelength range of level 1, which is a slight threat and indicates that a certain amount of internal gear or bearing wear may occur, and further observation is subsequently required, and if a more serious threat level appears after a later period of use, disassembly and maintenance are required.

6. The portable closed gearbox anomaly discrimination method as claimed in claim 4, wherein said step S4, a yellow light is lighted in the 2-class wavelength range, which is a moderate threat, indicating that the internal gears or bearings have been damaged to some extent.

7. The portable closed gearbox abnormity discrimination method according to claim 4, wherein in the step S4, a red light is lighted within a 3-level wavelength range, which is a serious threat and indicates that the internal structure of the reduction gearbox has serious destructive damage and needs to be stopped and overhauled in time.