Large and medium-sized machine operation state monitoring system
Technical Field
The invention relates to the technical field of large and medium-sized machine safety, in particular to a large and medium-sized machine operation state monitoring system.
Background
With the continuous progress of industrial technology, the large-scale construction of infrastructure is more and more, the large-scale aloft work is more and more, and the development of a large number of ultrahigh engineering construction projects promotes the requirement of ultrahigh hoisting work to be increased; the large-scale hoisting service is mainly applied to downstream industries such as ocean engineering equipment, electric power construction, aerospace engineering, infrastructure construction, coal chemical industry, petrochemical industry, metallurgical construction and the like, and the hoisting height of the large-scale hoisting service exceeds 120 meters.
However, the hoisting operation with the ultrahigh height has a greater and greater hoisting risk; the unsafe factors include the hoisting weight of the crane, safety problems among the cranes, external environmental factors and the like.
The method specifically comprises the following steps: when a plurality of cranes perform simultaneous cross operation, such as simultaneous cross operation of a plurality of tower cranes or simultaneous cross operation of a tower crane and a crawler crane, the mutual collision between the arm frames of the plurality of cranes and between the arm frame and the steel wire rope of the lifting hook is very easy to occur in the working process, and safety accidents are caused.
In addition, the influence of the wind speed in the external environment on the high-altitude hoisting operation is avoided; the wind speed is very obvious to the high altitude hoist and mount operation, and in the hoist and mount process of loop wheel machine, hoist and mount iron tower and hang the piece (including other objects) and all can all receive the wind speed influence, and wind-force causes the work arm and the hoisting member of hoist and mount operation equipment to swing (shake), directly influences operation work safety. Therefore, in the specification of hoisting operation, it is generally specified that the hoisting operation machine should stop working immediately when the wind speed is higher than 10.8m/s and strong wind or gust occurs. In the practical application process, however, a plurality of uncertain factors can occur; for example, whether the wind power borne by the ultra-high air is crosscut wind with the ground or not and whether the direction of the wind power is consistent or not are uncertain, and the influence of the crosscut wind on the hoisting operation is much larger than the damage of the pure wind power in the same wind direction; on the other hand, the same limited wind speed is adopted for hoisting operation equipment with different heights, and the method is still favorable for hoisting operation equipment with small relative height difference; however, for the existing ultrahigh hoisting operation equipment, the weather conditions and the wind speed of the top surface are possibly different from the ground, and the top surface is limited according to the uniform wind speed, which is obviously unreasonable; and how to identify the wind direction coupled with the wind speed is a problem which is worthy of being solved, so that research and improvement on the problem are needed.
Disclosure of Invention
The invention provides a large and medium-sized machine operation state monitoring system, which solves the problem that large and medium-sized machines in the prior art cannot monitor and early warn in real time, and comprises the load of a crane, the collision prevention among the cranes and the influence of external environmental factors on the hoisting process.
The technical scheme adopted for solving the problems in the prior art is as follows:
the large and medium-sized machinery comprises a crane, an information acquisition layer, an information transmission layer and a data service platform, wherein the information transmission layer is used for data transmission and communication between the information acquisition layer and the data service platform; the information acquisition layer comprises a plurality of acquisition terminals for acquiring data, and each acquisition terminal comprises a weight sensor, a radar sensor, a wind speed measuring instrument, an angle sensor, an amplitude sensor, a height encoder, an azimuth sensor and a high-definition camera; the information transmission layer comprises a GPRS module and/or a transmission cable to realize the transmission of wireless and/or wired signals; the data service platform sets an early warning value and a limit value according to the requirements of safe operation regulations of the crane and monitors and judges the acquired data.
Further, the weight sensor comprises a three-pulley type sensor arranged on the fixed pulley system and/or a plate ring type sensor arranged on a bearing support of the winding drum and used for detecting the hoisting weight of the crane, and when the weight sensor is the three-pulley type sensor, a steel rope for hoisting a heavy object by the crane passes through the three-pulley type sensor; through the setting of the sensor of different grade type can be better the loop wheel machine of adaptation different grade type, also or through the setting increase weighing accuracy and reliability of two sensors.
Specifically, the precision of the weight sensor is that the weight display error is less than or equal to +/-3 percent and is not more than 0.5 t; the high-precision weight sensor ensures the accuracy of overload early warning and ensures the safety to a greater extent.
Furthermore, a plurality of radar sensors are arranged on an arm support of the cranes to detect the distance between adjacent cranes and prevent the cranes from colliding in a cross operation range, and the plurality of radar sensors are uniformly arranged on the arm support through a connecting device; the distance between the current adjacent cranes detected by each radar sensor is subjected to multiple alarming according to the early warning value and the limit value set in the data service platform; when the distance between adjacent cranes reaches a set limit value, the arm support of the crane stops and rotates to the side far away from the adjacent crane.
Specifically, the radar sensor is fixedly connected to the side wall of the boom rod of the crane boom through a connecting device, the connecting device comprises a connecting buckle, the connecting buckle is arranged on the side wall of the boom rod of the crane boom, and a connecting plate for fixedly connecting the radar sensor is arranged on the connecting buckle; the connecting buckles positioned on the two sides of the boom rod of the crane boom are connected through the connecting column; the connector link is provided with a plurality of first connecting holes for connecting the connecting columns and second connecting holes for the cables to pass through.
Preferably, each connecting column is connected with two connecting buckles, and one or more connecting plates can be arranged on each connecting buckle.
Preferably, the connecting buckle is L-shaped and comprises a first buckle plate and a second buckle plate, the first buckle plate is used for being connected with the connecting plate, and the second buckle plate is used for being connected with an arm rod of the crane boom.
Furthermore, the adjacent cranes are simultaneously provided with the same number of radar sensors, every two radar sensors between the two adjacent cranes form a group, and a plurality of groups of radar sensors are arranged according to the cross operation range between the two adjacent cranes.
Further, the anemometer is arranged at the top end and/or the bottom end of the crane.
Furthermore, the wind speed measuring instruments are respectively and simultaneously installed at the open positions at the top end and the bottom of the crane, namely a first wind speed measuring instrument is arranged at the top of a lifting pulley of the crane, and a second wind speed measuring instrument is also arranged at any open position around the bottom of the crane; collecting a wind speed signal of the position of a lifting pulley of the crane by a first wind speed measuring instrument, and collecting a wind speed signal around the bottom of the crane by a second wind speed measuring instrument; and the data service platform processes the data of the first anemometer and the second anemometer.
Further, the processing the data of the first anemometer and the second anemometer includes: setting the wind speed signal collected by the first wind speed measuring instrument as a high-rise wind speed signal, setting the wind speed signal collected by the second wind speed measuring instrument as a low-rise wind speed signal, performing vector superposition on the high-rise wind speed signal and the low-rise wind speed signal to form a comprehensive wind speed signal, and judging the influence degree of the wind speed on the operation of the crane through the comprehensive wind speed signal so as to determine whether the condition of early warning or stopping the operation is met.
Furthermore, the collection terminal routing is along a fixed rope, the length of the collection terminal signal line is slightly greater than that of the fixed rope, and the fixed rope is fixed on the arm support; and a signal wire on the acquisition terminal is vertically led out.
Further, the data transmitted to the data service platform through wireless and/or wired signals are synchronized to display the data of the crane in the field operation environment at the mobile phone end in real time.
The beneficial effects are as follows:
the invention solves the problem that large and medium-sized machinery in the prior art can not be monitored and early-warned in real time, and comprises the load of a crane, collision prevention among the cranes and the influence of external environmental factors on the hoisting process.
Drawings
FIG. 1 is a schematic view of a crane in an operating state;
FIG. 2 is a schematic view of the installation structure of the radar sensor on the arm support;
FIG. 3 is a schematic view of the installation position of the anemometer;
FIG. 4 is a schematic view of the cross operation range between the flat-arm tower crane and the crawler crane.
Detailed Description
The present invention will be further described with reference to the following embodiments. Wherein the showings are for the purpose of illustration only and are shown by way of illustration only and not in actual form, and are not to be construed as limiting the present patent; to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
Example 1
The embodiment provides a monitoring system for the operating state of large and medium-sized machinery, wherein the large and medium-sized machinery in the embodiment is a flat-arm tower crane and comprises an information acquisition layer, an information transmission layer and a data service platform, wherein the information transmission layer is used for data transmission and communication between the information acquisition layer and the data service platform; the information acquisition layer comprises a plurality of acquisition terminals for acquiring data, and each acquisition terminal comprises a weight sensor, a radar sensor, a wind speed measuring instrument, an angle sensor, an amplitude sensor, a height encoder, an azimuth sensor and a high-definition camera; the information transmission layer comprises a GPRS module and/or a transmission cable to realize wireless and/or wired signal transmission; the data service platform sets an early warning value and a limit value according to the requirements of safe operation regulations of the crane and monitors and judges the acquired data.
As shown in figure 1, the weight sensor in the embodiment comprises a plate ring type sensor arranged on the bearing support 2 of the winding drum and used for detecting the hoisting weight of the crane, and the precision of the weight sensor is that the weight display error is less than or equal to +/-3 percent and is not more than 0.5 t.
As shown in fig. 1-2, in the embodiment, four radar sensors 21, 22, 23, and 24 are disposed on the arm support 13 of the crane 1 to detect the distance between adjacent cranes and prevent collision between the cranes in the cross operation range; the four radar sensors are uniformly arranged on the arm support 13 through a connecting device; the distance between the current adjacent cranes detected by each radar sensor is subjected to multiple alarming according to the early warning value and the limit value set in the data service platform; when the distance between adjacent cranes reaches a set limit value, the arm support of the crane stops and rotates to the side far away from the adjacent crane.
In the embodiment, the four radar sensors 21, 22, 23 and 24 are all fixedly connected to the side wall of the arm support 13 through a connecting device, the connecting device comprises a connecting buckle 4, a connecting plate 6 for fixedly connecting the radar sensors is arranged on the connecting buckle 4, and the connecting buckle 4 is connected through a connecting column 5; the connecting buckle 4 is L-shaped and comprises a first buckle plate 43 and a second buckle plate 43, the first buckle plate 42 is used for connecting the connecting plate 6, and the second buckle plate 43 is used for connecting the arm support 13.
As shown in fig. 3, in the present embodiment, the wind speed measuring instruments are respectively and simultaneously installed at the top and bottom open positions of the crane, that is, the first wind speed measuring instrument 7 is installed at the top of the lifting pulley of the crane, and the second wind speed measuring instrument 8 is also installed at any open position around the bottom of the crane; collecting a wind speed signal of the position of a lifting pulley of the crane by a first wind speed measuring instrument 7, and collecting a wind speed signal around the bottom of the crane by a second wind speed measuring instrument 8; the data service platform processes the data of the first anemoscope 7 and the second anemoscope 8, and the specific processing process includes: setting the wind speed signal collected by the first wind speed measuring instrument 7 as a high-rise wind speed signal, setting the wind speed signal collected by the second wind speed measuring instrument 8 as a low-rise wind speed signal, performing vector superposition on the high-rise wind speed signal and the low-rise wind speed signal to form a comprehensive wind speed signal, and judging the influence degree of the wind speed on the operation of the crane through the comprehensive wind speed signal so as to determine whether the condition of early warning or stopping the operation is met.
In this embodiment, the collection terminal is wired along a fixed rope, the length of the collection terminal signal line is slightly greater than the length of the fixed rope, and the fixed rope is fixed on the arm support; and a signal wire on the acquisition terminal is vertically led out.
In this embodiment, the data transmitted to the data service platform via the wired signal is synchronized at the mobile phone end to display the data in the field operation environment of the crane in real time.
Example 2
The difference from embodiment 1 is that the crane in this embodiment is a crawler crane, the weight sensor in this embodiment is a three-pulley sensor, and the three-pulley sensor is disposed on a fixed pulley system, and is fixedly mounted on the arm support through a mounting bracket, and is matched with the pulley system on the crane, and a steel rope for the crane to lift a heavy object passes through the three-pulley sensor.
Example 3
In this embodiment, an anticollision working process between flat arm tower crane and crawler crane is provided, as follows: as shown in fig. 4, the swing direction of the tower type fly jib of the crawler crane is shown by the line N in fig. 4, the swing track of the tower type fly jib of the crawler crane is shown by the line S in fig. 4, and the cross working range of the crawler crane and the flat-arm tower crane is shown by the area M in fig. 4.
The radar sensor 2 used in the embodiment is a millimeter wave radar sensor, the wavelength of millimeter waves is between centimeter waves and light waves, and the millimeter wave radar sensor has the advantages of microwave guidance and photoelectric guidance, is small in size, easy to integrate, but high in spatial resolution, and is convenient to improve the accuracy of detection. The detection range of the radar sensor to the small-sized obstacles is 0.7-10 m, and the detection range of the radar sensor to the large-sized obstacles is 0.7-30 m; in the embodiment, the detection range of the radar sensor is respectively 50 degrees from the left to the right by taking the vertical central axis of the radar sensor as a reference, namely the detection horizontal coverage angle of the radar sensor is 100 degrees; in this embodiment, the detection range of the radar sensor is 7 degrees respectively from top to bottom with the boom as a reference, that is, the detection pitch angle of the radar sensor is 14 degrees. The detection range and detection angle of the radar sensor can be set by those skilled in the art according to actual working conditions.
The safety detection distance and the early warning distance of the radar sensor are set through the display host, wherein the safety detection distance is set to be larger than 15m, and the early warning distance is set to be smaller than 15 m; and displaying the distance between the crane arm and the tower auxiliary arm detected by each radar sensor on a display host of the data service platform in real time, and giving an alarm when the distance is less than 15 m.
Wherein, send different alarm signals by alarm system in different distance ranges and carry out multiple alarm, multiple alarm specifically is triple alarm, send out the alarm respectively at 15m, 10m and 3.5m respectively, and when sending out the alarm of 3.5m, the jib loading boom stops and revolves to the side of keeping away from tower auxiliary arm.
It should be understood that the above examples are only for clearly illustrating the technical solutions of the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection of the claims of the present invention.