CN114282423A - Fatigue monitoring method and service life prediction method for shore bridge structure - Google Patents
Fatigue monitoring method and service life prediction method for shore bridge structure Download PDFInfo
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Abstract
The invention relates to a fatigue monitoring method and a service life prediction method for a shore bridge structure in the technical field of equipment performance monitoring, which comprises the following steps: establishing a shore bridge model, and analyzing macroscopic stress data of the shore bridge to obtain a first stress point set; establishing a finite element analysis model, inputting the first stress point set into the finite element analysis model to obtain a second stress point set; formulating a data acquisition scheme and acquiring actual stress data; obtaining time-period operation data of a shore bridge to obtain historical simulation data, and inputting the historical simulation data into a finite element analysis model to obtain model simulation stress data; verifying the reliability of the simulation stress data of the model according to the actual stress data, and correcting the shore bridge model and the finite element analysis model; and the simulation stress data of the correction model of the shore bridge is obtained according to the corrected finite element analysis model, and the stress spectrum is generated, so that the method has the advantage of high accuracy, and the bottleneck of inaccurate fatigue monitoring obtained by the traditional fatigue monitoring method is broken through.
Description
Technical Field
The invention relates to the technical field of equipment performance monitoring, in particular to a fatigue monitoring method and a service life prediction method for a shore bridge structure.
Background
In engineering practice, a shore bridge, also called as hoisting and transporting equipment, plays an irreplaceable role in economic construction, and hoisting machinery is stressed complexly in the operation process and is subjected to dynamic force generated in the process of hoisting and transporting goods and uncertain force such as wind load, earthquake load and the like, and various forces are superposed and act on the hoisting machinery, so that cracks appear on certain local stress concentration parts of the hoisting machinery, and the service life of the hoisting machinery is further influenced.
Meanwhile, after years of use, the port crane has more or less faults in the metal structure, fatigue cracks with different degrees appear although the service life is not reached, how much the fatigue degree of the crane can be used safely or not, and how long the crane can be used safely, which becomes a very concerned problem for the crane use department, along with the development of economy, the demand of the crane machinery is continuously enlarged, meanwhile, the crane machinery is continuously developed towards large-scale and complex, the crane accidents and risk factors are continuously increased, the crane accidents and the risk factors enter the later service stage or the beyond service stage, the probability of fatigue damage of the crane with structural damage per se is quite large, and the potential threat to safety production is formed.
Aiming at the safety threat, the traditional method for monitoring the fatigue degree of the crane on line often has the problem that the accuracy of fatigue monitoring cannot be guaranteed because the actual operation condition of the crane is not considered, and further the service life prediction of the crane and the establishment of a maintenance scheme are influenced.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a fatigue monitoring method and a service life prediction method for a shore bridge structure, which have the advantages of high accuracy and break through the bottleneck of inaccurate fatigue monitoring obtained by the traditional fatigue monitoring method.
In order to solve the technical problem, the invention is solved by the following technical scheme:
a fatigue monitoring method for a shore bridge structure comprises the following steps:
establishing a shore bridge model, and analyzing macroscopic stress data of the shore bridge according to the shore bridge model to obtain a first stress point set;
establishing a finite element analysis model, and inputting the first stress point set into the finite element analysis model to obtain a second stress point set;
formulating a data acquisition scheme according to the second stress point set, and acquiring actual stress data according to the data acquisition scheme;
acquiring time period operation data of the shore bridge, acquiring historical simulation data according to the time period operation data, and inputting the historical simulation data into a finite element analysis model to acquire model simulation stress data of the shore bridge in each operation period;
verifying the reliability of the simulation stress data of the model according to the actual stress data, and correcting the shore bridge model and the finite element analysis model;
and obtaining corrected model simulation stress data of the shore bridge according to the corrected finite element analysis model, and generating a stress spectrum according to the corrected model simulation stress data.
Optionally, establishing a shore bridge model, and analyzing macro stress data of the shore bridge according to the shore bridge model to obtain a first stress point set, including the following steps:
obtaining a structural drawing and operation data of a shore bridge, and constructing a shore bridge model according to the structural drawing;
inputting the operation data into a shore bridge model, and outputting macroscopic stress data of the shore bridge after the operation data is input, so as to obtain a first stress point set.
Optionally, establishing a finite element analysis model, and inputting the first stress point set into the finite element analysis model to obtain a second stress point set, including the following steps:
obtaining a structural drawing of a shore bridge, and constructing a finite element analysis model according to the structural drawing;
inputting the first stress point set into a finite element analysis model, and acquiring node stress concentration points according to the finite element analysis model;
and defining a dangerous area according to the concentration of the stress concentration points and the stress amplitude to obtain a second stress point set.
Optionally, a data acquisition scheme is formulated according to the second set of stress points, including the following steps:
determining a plurality of acquisition installation positions according to the second stress point set, and installing sensors on the acquisition installation positions;
and acquiring actual stress data of each acquisition installation part acquired by each group of sensors, wherein the actual stress data comprises stress data, displacement data and speed data.
Optionally, a data acquisition scheme is formulated according to the second set of stress points, and the method further includes the following steps:
and generating an actual stress-displacement cloud picture according to the stress data, the displacement data and the speed data.
Optionally, the obtaining of the time period operation data of the shore bridge and obtaining of the historical simulation data according to the time period operation data includes the following steps:
collecting container parameters of a container carried by a shore bridge in any time period, and acquiring shore bridge operation data of different containers in the time period according to the container parameters to obtain time period operation data;
and according to the time period operation data, performing statistical simulation on the historical shore bridge operation data of all containers to obtain historical simulation data.
Optionally, verifying the reliability of the simulation stress data of the model according to the actual stress data, and correcting the shore bridge model and the finite element analysis model, including the following steps:
comparing whether the model simulation stress data is consistent with the actual stress data;
if so, the simulation stress data of the model is reliable, and the simulation stress data of the model is reserved in the shore bridge model and the limited analysis model;
if not, the simulation stress data of the model is unreliable, and the shore bridge model and the limited analysis model are corrected according to the actual stress data.
Optionally, comparing whether the model simulation stress data is consistent with the actual stress data includes the following steps:
and outputting a simulated stress-displacement cloud picture according to the simulated stress data of the model, and comparing whether the actual stress-displacement cloud picture is the same as the simulated displacement cloud picture.
A life prediction method for a shore bridge structure comprises the following steps:
obtaining design parameters of a shore bridge, and outputting a stress fatigue curve according to the design parameters;
constructing a life prediction model according to the linear fatigue damage model and the stress fatigue curve, wherein the life prediction model takes a stress spectrum as data input;
and outputting a life prediction curve according to the life prediction model, and obtaining a life value of the shore bridge.
Optionally, the method further comprises the following steps:
and outputting a maintenance and inspection scheme of the shore bridge according to the service life prediction model.
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
the method comprises the steps of establishing a shore bridge model to obtain a macroscopic first stress point set of the shore bridge through a structure drawing and operation data based on the actual shore bridge, using the first stress point set as input of a finite element analysis model, gradually acquiring a second stress point set more accurate than the first stress point set, obtaining actual stress data according to a formulated data acquisition scheme, using the actual stress data as reliability verification of simulation stress data, correcting the finite element analysis model through the reliability verification, improving the accuracy of the finite element analysis model, and enabling the accuracy of the obtained stress spectrum to be higher.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
Fig. 1 is a flowchart of a fatigue monitoring method for a shore bridge structure according to an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to examples, which are illustrative of the present invention and are not to be construed as being limited thereto.
Example one
As shown in fig. 1, a fatigue monitoring method for a shore bridge structure includes the following steps: establishing a shore bridge model, and analyzing macroscopic stress data of the shore bridge according to the shore bridge model to obtain a first stress point set, which specifically comprises the following steps: obtaining a structural drawing and operation data of a shore bridge, and constructing a shore bridge model according to the structural drawing; inputting the operation data into a shore bridge model, and outputting macroscopic stress data of the shore bridge after the operation data is input, so as to obtain a first stress point set.
When the stress point analysis of the shore bridge structure is carried out, firstly, a shore bridge model is established by using OpenSees, the shore bridge model uses a structure drawing of a shore bridge as input data of the model, so that a real shore bridge and the operation process of the shore bridge are simulated in the shore bridge model, wherein the structure drawing of the shore bridge comprises a beam structure and a node structure of the shore bridge, after the construction of the shore bridge model is completed, the operation data is required to be input into the shore bridge model, the established shore bridge model can be subjected to stress condition analysis, macroscopic stress data are obtained, the macroscopic stress data refer to an approximate stress position on the shore bridge in the shore bridge model, the approximate stress position can be located on the beam structure or on the node structure, the approximate stress position is a first stress point, and the obtained summary of the first stress points is a first stress point set.
Establishing a finite element analysis model, inputting the first stress point set into the finite element analysis model, and obtaining a second stress point set, specifically comprising the following steps: obtaining a structural drawing of a shore bridge, and constructing a finite element analysis model according to the structural drawing; inputting the first stress point set into a finite element analysis model, and acquiring node stress concentration points according to the finite element analysis model; and defining a dangerous area according to the concentration of the stress concentration points and the stress amplitude to obtain a second stress point set.
When a finite element analysis model is established, the same structural drawing of a shore bridge is used as input data of the model, the structural drawing comprises each node structure and a beam structure of the shore bridge, the node structure is a connection point of each bridge of the shore bridge in the shore bridge structure, when the finite element analysis model is established, ABAQUS is used for establishing, after the finite element analysis model is established, a first stress point set is input into the finite element analysis model, so that the stressed part of each first stress point is further determined in the finite element analysis model, a second stress point, namely a node stress concentration point, is obtained, each first stress point can obtain a plurality of node stress concentration points, the node stress concentration points are counted, the statistics is carried out according to the concentration principle of the stress concentration points and the stress amplitude, and the stress concentration points with high concentration and high stress amplitude are used as the second stress points, and the area where the second stress point is located is divided into dangerous areas.
Formulating a data acquisition scheme according to the second stress point set, and acquiring actual stress data according to the data acquisition scheme, specifically, the method comprises the following steps: determining a plurality of acquisition and installation positions according to the second stress point set, and installing sensors on the acquisition and installation positions; and acquiring actual stress data of each acquisition mounting part acquired by each group of sensors, wherein the actual stress data comprises stress data, displacement data and speed data.
According to the obtained collection installation part, various installation parts needing stress strain, displacement, speed and the like and needing to be detected are subjected to sensor installation, and points are reselected for the collection installation part which is ultrahigh and cannot be operated, and the principle of reselecting the points is that the collection installation part is easy to install and check or points which have great correlation with the original position, so that the collection installation part can be subjected to cross validation.
To the sensor of installing, belong to trigger type sensor, can realize the simultaneous acquisition measurement, and the sensor is when carrying out transmission data, adopt low-power consumption wireless transmission's mode to transmit, and the sensor sets for has certain collection frequency, accomplish data acquisition back at the sensor simultaneously, can carry out record and database storage action, and what the sensor mainly gathered is that the stress data of gathering the installation position, displacement data and speed data, then according to stress data, displacement data and speed data generation actual stress-displacement cloud picture.
The method comprises the following steps of obtaining time period operation data of a shore bridge, and obtaining historical simulation data according to the time period operation data, specifically: collecting container parameters of a container transported by a shore bridge in any time period, and acquiring shore bridge operation data of different containers in any time period according to the container parameters to obtain time period operation data; and according to the time period operation data, performing statistical simulation on the historical shore bridge operation data of all containers by a Monte Carlo method to obtain historical simulation data, and then inputting the historical simulation data into a finite element analysis model to obtain model simulation stress data of the shore bridge in each operation period.
Wherein, the container parameters comprise the serial number of the container, the weight of the container and other basic parameter data of some containers, the time interval of any time period can be set as one year, then the shore bridge operation data of the numbered container is obtained according to the container serial number in the container parameters, the shore bridge operation data comprises the motor torque of the shore bridge, the container operation speed and the like when the numbered container is operated, the time period operation data is the shore bridge operation data corresponding to each numbered container in the time period, then the Monte Carlo method is used to carry out statistical simulation on the container weight corresponding to each numbered container, the motor torque of the shore bridge and the shore bridge operation speed to obtain the operation data of the shore bridge equipment from the start of use, namely historical simulation data, and finally the historical simulation data is input as the data of the finite element analysis model, thereby obtaining the model simulation stress data of the shore bridge in each operation cycle of each container in the finite element analysis model, the operation cycle described in this embodiment is a process in which the shore bridge lifts a container from a lifting position to a transporting position, then puts down the container, and finally returns to the original position of the shore bridge.
It should be noted that, because some ports do not store a large amount of operation data, and only have information such as the number and the weight of the container, the probability distribution such as the speed and the displacement of the shore bridge when operating different containers is obtained through the existing shore bridge operation data statistics in a certain period of time, and the operation data corresponding to the information such as the number and the weight of the container from the beginning of the use of the shore bridge to the present can be simulated by using the monte carlo method.
Verifying the reliability of the simulation stress data of the model according to the actual stress data, and correcting the shore bridge model and the finite element analysis model, specifically, the method comprises the following steps: comparing whether the simulation stress data of the model is consistent with the actual stress data; if so, the simulation stress data of the model is reliable, and the simulation stress data of the model is reserved in the shore bridge model and the limited analysis model; and if not, the simulation stress data of the model is unreliable, and the shore bridge model and the finite element analysis model are corrected according to the actual stress data, wherein the shore bridge model is used as the front end of the finite element analysis model, and the finite element analysis model needs to be input as data by means of the first stress point set in the shore bridge model, so that the shore bridge model needs to be corrected together when the shore bridge model needs to be corrected.
Wherein, whether the simulation stress data of the comparison model is consistent with the actual stress data comprises the following steps: and outputting a simulated stress-displacement cloud picture according to the simulated stress data of the model, and comparing whether the actual stress-displacement cloud picture is the same as the simulated displacement cloud picture.
The accuracy of the simulated stress-displacement cloud picture is verified by performing cross verification on the simulated stress-displacement cloud picture obtained through simulation and the actual stress-displacement cloud picture, when the simulated stress-displacement cloud picture and the actual stress-displacement cloud picture are not consistent in comparison, corresponding parts can be analyzed and checked, the finite element analysis model is corrected until a more accurate simulated stress-displacement cloud picture is obtained, corrected model simulation stress data of the shore bridge are obtained according to the corrected finite element analysis model after the simulated stress-displacement cloud picture with the required accuracy is achieved, a stress spectrum is generated by using a rain flow counting method according to the corrected model simulation stress data, and therefore the fatigue degree of the structure of the shore bridge is obtained according to the stress spectrum.
Example two
A life prediction method for a shore bridge structure comprises the following steps: obtaining design parameters of a shore bridge, and outputting a stress fatigue curve according to the design parameters; constructing a life prediction model according to the linear fatigue damage model and the stress fatigue curve, wherein the life prediction model is input as data through a stress spectrum; outputting a life prediction curve according to the life prediction model and obtaining a life value of the shore bridge, and further comprising the following steps of: and outputting a maintenance and inspection scheme of the shore bridge according to the service life prediction model.
In this embodiment, the establishment of the life prediction model first needs to acquire the stress spectrum output by the finite element analysis model obtained in the first embodiment as the input of the life prediction model, and the acquisition of the stress spectrum is obtained according to the method of the first embodiment, which is not described in detail in this embodiment, so that the fatigue degree of the obtained shore bridge structure is more accurate and the life prediction of the shore bridge structure is more accurate through the combination of the linear fatigue damage model, the stress fatigue curve and the stress spectrum.
On the other hand, when an abnormal condition occurs, such as an earthquake, a hook accident, an impact, an undetected crack and a crack failure maintenance condition, the stress of the abnormal condition needs to be recalculated by using the finite element analysis model, a stress spectrum under the abnormal condition is obtained, and the finite element analysis model and the service life prediction model are corrected.
And when the service life prediction model shows that the service life of the shore bridge is due, combining the actual stress data collected by the sensor and the finite element analysis model, calculating to dynamically prolong or using the same actual stress data as the input of the test block to perform the fatigue test of the test block, and giving maintenance inspection suggestions to the service life reference value output by the service life prediction model obtained by the fatigue test.
In addition, it should be noted that the specific embodiments described in the present specification may differ in the shape of the components, the names of the components, and the like. All equivalent or simple changes of the structure, the characteristics and the principle of the invention which are described in the patent conception of the invention are included in the protection scope of the patent of the invention. Various modifications, additions and substitutions for the specific embodiments described may be made by those skilled in the art without departing from the scope of the invention as defined in the accompanying claims.
Claims (10)
1. A fatigue monitoring method for a shore bridge structure is characterized by comprising the following steps:
establishing a shore bridge model, and analyzing macroscopic stress data of the shore bridge according to the shore bridge model to obtain a first stress point set;
establishing a finite element analysis model, and inputting the first stress point set into the finite element analysis model to obtain a second stress point set;
formulating a data acquisition scheme according to the second stress point set, and acquiring actual stress data according to the data acquisition scheme;
acquiring time period operation data of the shore bridge, acquiring historical simulation data according to the time period operation data, and inputting the historical simulation data into a finite element analysis model to acquire model simulation stress data of the shore bridge in each operation period;
verifying the reliability of the simulation stress data of the model according to the actual stress data, and correcting the shore bridge model and the finite element analysis model;
and obtaining corrected model simulation stress data of the shore bridge according to the corrected finite element analysis model, and generating a stress spectrum according to the corrected model simulation stress data.
2. The fatigue monitoring method for the shore bridge structure according to claim 1, wherein a shore bridge model is established, and macroscopic stress data of the shore bridge is analyzed according to the shore bridge model to obtain the first stress point set, and the method comprises the following steps:
obtaining a structural drawing and operation data of a shore bridge, and constructing a shore bridge model according to the structural drawing;
inputting the operation data into a shore bridge model, and outputting macroscopic stress data of the shore bridge after the operation data is input, so as to obtain a first stress point set.
3. The method for monitoring fatigue of a shore bridge structure, according to claim 1, wherein a finite element analysis model is established, the first set of stress points is inputted into the finite element analysis model, and the second set of stress points is obtained, comprising the following steps:
obtaining a structural drawing of a shore bridge, and constructing a finite element analysis model according to the structural drawing;
inputting the first stress point set into a finite element analysis model, and acquiring node stress concentration points according to the finite element analysis model;
and defining a dangerous area according to the concentration of the stress concentration points and the stress amplitude to obtain a second stress point set.
4. The method for monitoring fatigue of a shore bridge structure according to claim 1, wherein a data acquisition scheme is formulated according to the second set of stress points, comprising the steps of:
determining a plurality of acquisition installation positions according to the second stress point set, and installing sensors on the acquisition installation positions;
and acquiring actual stress data of each acquisition installation part acquired by each group of sensors, wherein the actual stress data comprises stress data, displacement data and speed data.
5. The method for monitoring fatigue of a shore bridge structure, according to claim 4, wherein a data acquisition scheme is formulated according to said second set of stress points, further comprising the steps of:
and generating an actual stress-displacement cloud picture according to the stress data, the displacement data and the speed data.
6. The fatigue monitoring method for the shore bridge structure, according to claim 1, wherein the time period operation data of the shore bridge is obtained, and the historical simulation data is obtained according to the time period operation data, and the method comprises the following steps:
collecting container parameters of a container carried by a shore bridge in any time period, and acquiring shore bridge operation data of different containers in the time period according to the container parameters to obtain time period operation data;
and according to the time period operation data, performing statistical simulation on the historical shore bridge operation data of all containers to obtain historical simulation data.
7. The fatigue monitoring method for the shore bridge structure according to claim 5, wherein the reliability of the simulation stress data of the model is verified according to the actual stress data, and the shore bridge model and the finite element analysis model are modified, comprising the following steps:
comparing whether the model simulation stress data is consistent with the actual stress data;
if so, the simulation stress data of the model is reliable, and the simulation stress data of the model is reserved in the shore bridge model and the limited analysis model;
if not, the simulation stress data of the model is unreliable, and the shore bridge model and the limited analysis model are corrected according to the actual stress data.
8. The fatigue monitoring method for the shore bridge structure according to claim 7, wherein the step of comparing whether the model simulation stress data is consistent with the actual stress data comprises the following steps:
and outputting a simulated stress-displacement cloud picture according to the simulated stress data of the model, and comparing whether the actual stress-displacement cloud picture is the same as the simulated displacement cloud picture.
9. A life prediction method of a shore bridge structure is characterized by comprising the following steps:
obtaining design parameters of a shore bridge, and outputting a stress fatigue curve according to the design parameters;
constructing a life prediction model according to the linear fatigue damage model and the stress fatigue curve, wherein the life prediction model takes a stress spectrum as data input;
and outputting a life prediction curve according to the life prediction model, and obtaining a life value of the shore bridge.
10. The method for predicting the life of a shore bridge structure, according to claim 9, further comprising the steps of:
and outputting a maintenance and inspection scheme of the shore bridge according to the service life prediction model.
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