CN117890006A - Bucket wheel machine walking wheel pressure monitoring and display system - Google Patents
Bucket wheel machine walking wheel pressure monitoring and display system Download PDFInfo
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Abstract
The invention discloses a system for monitoring and displaying the pressure of a traveling wheel of a bucket wheel machine, which relates to the technical field of stability detection of bucket wheel stacker-reclaimer equipment.
Description
Technical Field
The invention relates to the technical field of stability detection of bucket-wheel stacker reclaimer equipment, in particular to a pressure monitoring and displaying system of a traveling wheel of a bucket-wheel stacker reclaimer.
Background
In the running process of the bucket wheel machine, because of the factors of large load fluctuation, complex working conditions and severe environment, especially dust and the like, the increase of the scale deposit load and the accumulation load, especially the increase of the accumulation near the bucket wheel device, greatly changes the integral overturning moment and the gravity center position of the equipment. This may lead to increased wear of the slewing bearing, a large increase in partial wheel pressure, a break in the running wheel bearings and a reduced service life, possibly even risking tipping of the apparatus. Therefore, after the bucket wheel machine runs for a certain period, the bucket wheel machine needs to be detected to judge whether the working state of the equipment meets the operation standard, so that the influence on the overall balance of the bucket wheel machine due to the fact that the wheel pressure of the bucket wheel machine is too large or too small is avoided.
At present, a system for detecting the wheel pressure of a bucket wheel machine uses hydraulic jacks to jack up running wheel sets respectively, and the wheel pressure under specific working conditions is measured according to jack reading. However, this approach requires additional jacking support structures and is not necessarily located at the center of gravity of the wheelset. To measure the wheel pressure of the whole machine, at least four operations are required, each operation requires a position change, and only one set of wheel pressure can be measured at a time. Furthermore, measuring wheel pressure alone does not provide comprehensive data. Therefore, the existing detection method has a series of problems in the aspect of wheel pressure detection of the bucket wheel machine, including complex operation, low efficiency and insufficient data accuracy.
Disclosure of Invention
In order to solve the problems, namely a series of problems of complex operation, low efficiency and insufficient data accuracy existing in the aspect of wheel pressure detection of a bucket wheel machine in the existing detection method, the invention provides a bucket wheel machine running wheel pressure monitoring and displaying system which comprises a real-time acquisition module, a strain detection module, a wheel pressure basic database building module, a wheel pressure monitoring module, a comparison analysis module and a display module;
The real-time acquisition module is responsible for acquiring weight data of all parts of the bucket wheel machine before assembly in real time, acquiring overall weight data and load condition data again after hoisting and assembling, and transmitting initial data to the wheel pressure database building module respectively according to running wheel pressure, pitching and rotating device posture data of the bucket wheel machine under different working conditions; the module is also used for collecting real-time wheel pressure data of each supporting leg in the bucket wheel machine running system to be detected and transmitting the real-time wheel pressure data to the strain detection module;
The strain detection module is used for analyzing the real-time wheel pressure data received from the real-time acquisition module by utilizing a strain detection technology to acquire strain data of a running wheel track when each component forming the bucket wheel machine is assembled; calculating the strain data to obtain real-time wheel pressure data of the newly assembled bucket wheel machine, and transmitting the real-time wheel pressure data to a wheel pressure monitoring module; the attitude data of the bucket wheel machine can be accurately judged by utilizing the strain detection technology and combining with the signal feedback of the original equipment on the bucket wheel machine, and the attitude data is transmitted to the comparison analysis module;
The wheel pressure basic database building module is used for receiving the initial data transmitted by the real-time acquisition module; the total force and the whole weight of the whole running system are obtained through data conversion of the initial data, and the wheel pressure condition data of the running wheels and the wheel sets are determined; calculating wheel pressure limit data of the running wheel through materials and structures selected when the bucket wheel machine is designed, and transmitting the wheel pressure limit data to a wheel pressure monitoring module; storing initial data, wheel pressure condition data and wheel pressure limit data into a database, and establishing a wheel pressure basic database of the bucket wheel machine under any working condition; in the module, transmitting initial data and wheel pressure limit data to a comparison analysis module;
The wheel pressure monitoring module is used for converting the real-time wheel pressure data received from the strain detection module into a waveform chart which is displayed in real time; and comparing the waveform data in the waveform diagram with the wheel pressure limit data received from the wheel pressure basic database building module, and triggering an alarm when the waveform data exceeds the wheel pressure limit data.
The comparison analysis module is used for comparing and analyzing the gesture data received from the strain detection module with the initial gesture data received from the wheel pressure basic database building module so as to determine the current working state of the bucket wheel machine; extracting initial wheel pressure data of the bucket wheel machine with the determined working state in a wheel pressure basic database building module; setting initial wheel pressure data in a wheel pressure basic database building module as lower limit, setting wheel pressure limit data as upper limit, comparing the upper limit and the lower limit with extracted wheel pressure data, and defining the wheel pressure data at the moment as normal wheel pressure data under normal working conditions if the extracted wheel pressure data falls in the interval; calculating and comparing the normal wheel pressure data with the initial wheel pressure data to obtain wheel pressure conditions, gravity center offset position data and overall stability data of the bucket wheel machine running system, and transmitting the results to a display module;
the display module is used for displaying the wheel pressure condition, the gravity center offset position data and the overall stability data of the bucket wheel machine running system received from the comparison analysis module.
Preferably, the initial data in the real-time acquisition module includes initial weight, overall weight, load conditions, initial wheel pressure, and initial attitude data.
Preferably, the attitude data in the strain detection module includes: pitch angle data and roll angle data.
Preferably, the wheel pressure basic database building module also simulates the wheel pressure change condition of the bucket turbine under various working conditions through finite ternary modeling and SOLIWORKS three-dimensional modeling, and stores the wheel pressure change condition in a database.
Preferably, the wheel pressure condition in the comparison analysis module includes: the wheel pressure of each wheel set, the wheel pressure of each running wheel and the gravity center position.
Preferably, the working conditions mentioned in the real-time acquisition module refer to: (1) in the material taking state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; (2) in a stacking state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; (3) in the no-load state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; in addition, the pitching angle of the bucket wheel machine pitching device can work between-16 degrees and +16 degrees, and the turning device angle is between-110 degrees and +110 degrees.
The beneficial technical effects of the invention are as follows:
1) The condition that each part of the bucket wheel machine is manufactured by independent design and can be preassembled is fully utilized. This advantage allows for comprehensive collection of turbine data at the factory to build a specialized turbine database.
2) And carrying out three-dimensional modeling according to the design drawing, and simulating the conditions of the bucket wheel machine in various working states. The method is favorable for better analyzing the working state of the bucket wheel machine and carrying out comprehensive calculation of various data, and ensures the accuracy and reliability of the detection data.
3) Compared with the traditional detection method, the method adopts an advanced strain detection technology, and greatly improves the detection efficiency. The technology effectively simplifies the detection process and converts the detection data into a waveform diagram which can be observed in real time. The wheel pressure change state during bucket wheel machine wheel pressure detection can be intuitively known by comparing the normal state waveform data in the bucket wheel machine special database.
4) By means of the running condition of the field bucket wheel machine, the safety condition of the wheel pressure can be simply analyzed. The method greatly improves the detection precision and makes the detection result more visual. The state monitoring and adjustment of the bucket wheel machine equipment are facilitated, so that the potential safety hazard of the equipment is reduced;
5) By setting the upper limit and the lower limit of the wheel pressure data, the wheel pressure data can be effectively screened. When the wheel pressure data is in a preset normal range, the system judges that the bucket wheel machine is in a normal working state. The automatic judging process is beneficial to finding potential problems in time, and the efficiency of monitoring and managing the state of the bucket wheel machine in real time is improved;
6) The wheel pressure monitoring module provides an alarm function and is beneficial to improving the safety of the bucket wheel machine. Through timely alarm, the user can respond quickly and take necessary measures to prevent the problem of the equipment caused by abnormal wheel pressure. This not only helps to protect the equipment itself, but also prevents potential workplace accidents, ensuring the safety of staff and equipment.
Drawings
Fig. 1 is a schematic diagram of a module composition structure of a system for monitoring and displaying the pressure of a traveling wheel of a bucket wheel machine according to the present embodiment;
fig. 2 is a waveform diagram of real-time wheel pressure data in the wheel pressure monitoring module according to the present embodiment.
Detailed Description
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are merely for explaining the technical principles of the present invention, and are not intended to limit the scope of the present invention.
In order to solve the problems of complex operation, low efficiency and insufficient data accuracy existing in the aspect of wheel pressure detection of a bucket wheel machine in the existing detection method, the invention provides the following technical scheme: a system for monitoring and displaying the pressure of running wheels of bucket wheel machine.
The strain analyzer of the embodiment is a sigma strain analyzer, which is connected to the track of the bucket wheel machine running wheel through a resistance strain gauge;
The strain analysis software of the embodiment is V2.5 version and is installed on a notebook computer;
the jack of the embodiment is a hydraulic jack;
In the embodiment, the bucket wheel machine is provided with supporting wheel groups at four corners of the door seat frame, and each wheel group consists of 6 traveling wheels, and the total number of the traveling wheels is 24. Two ends of the balance beam at two sides of the door seat frame are provided with two wheel sets, and each wheel set is provided with a primary wheel frame, a secondary wheel frame and three tertiary wheel frames. The wheel sets transmit the load borne by the supporting leg to 6 walking wheels on average through the hinge shafts of the wheel frames of all stages to form an hyperstatic system, so that the load is ensured to be uniformly dispersed on each walking wheel.
In terms of stress analysis, each leg should ideally be subjected to a uniformly dispersed load, respectively. The load distribution of the wheels in each set of wheelsets is a critical design consideration. Even under the condition of the offset of the gravity center, the stress of the 4 supporting points can still be kept relatively balanced, because the 6 walking wheels in each wheel set evenly share the pressure of the supporting leg.
Referring to fig. 1, the invention provides a system for monitoring and displaying the pressure of a traveling wheel of a bucket wheel machine, which comprises a real-time acquisition module, a strain detection module, a wheel pressure basic database building module, a wheel pressure monitoring module, a comparison analysis module and a display module.
The real-time acquisition module is responsible for acquiring weight data of all parts of the bucket wheel machine before assembly in real time, acquiring overall weight data and load condition data again after hoisting and assembling, and transmitting initial data to the wheel pressure database building module respectively according to running wheel pressure and posture data of pitching and turning devices of the bucket wheel machine under different working conditions, wherein the initial data comprises initial weight, overall weight, load condition, initial wheel pressure and initial posture data, and the wheel pressure is the running wheel pressure; collecting real-time wheel pressure data of each supporting leg in the bucket wheel machine running system to be detected through a jack, and transmitting the real-time wheel pressure data to a strain detection module; in addition, each bucket wheel machine produced in the module performs data acquisition once and updates an expansion database so as to ensure the true reliability of the data;
The working conditions mentioned herein refer to: (1) in the material taking state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; (2) in a stacking state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; (3) in the no-load state: the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation. In addition, the pitching angle of the bucket wheel machine pitching device can work between-16 degrees and +16 degrees, and the turning device angle is between-110 degrees and +110 degrees.
The strain detection module is used for analyzing the real-time wheel pressure data received from the real-time acquisition module by utilizing a strain detection technology to acquire strain data of a running wheel track when each component forming the bucket wheel machine is assembled; calculating the strain data to obtain real-time wheel pressure data of the newly assembled bucket wheel machine, and transmitting the real-time wheel pressure data to a wheel pressure monitoring module; the attitude data of the bucket wheel machine can be accurately judged by utilizing the strain detection technology in combination with feedback of sensors arranged on pitching and rotating devices in the bucket wheel machine and transmitted to a comparison analysis module, wherein the attitude data comprises the following components: pitch angle data and roll angle data.
The strain detection technology mentioned here is that the strain analyzer is attached to the detected track by using the resistance strain gauge, when the detected track bears the pressure deformation of the running system, the stress wave signals of the track are received by the stress sensors arranged on two sides of the track body, the processing force and time course (domain) curve are analyzed by using the stress wave theory so as to judge the bearing pressure of the running system and evaluate the running stability of the bucket wheel system, through the process, the strain analyzer provides real-time monitoring and evaluation of the track deformation and the bearing pressure, provides important information for the performance and the safety of the bucket wheel system, and can infer the attitude state of the bucket wheel system by monitoring the deformation or the strain condition of the bucket wheel. The method comprises the following steps:
Specific parameter settings for strain detection techniques are described herein, in a strain analyzer, the following parameters are entered:
1. bridge circuit configuration: half-bridge one-to-one compensation;
2. and (3) wire connection: six-wire manufacturing;
3. bridge source voltage: set to 2.5V;
4. strain gauge resistance: set to 120Ω;
5. range of measurement: the interval is-58823.5-66666.5;
6. Poisson ratio: set to 0.27;
7. Modulus of elasticity: set to 200;
8. Sampling rate: sampling 50 times per second;
These parameters will be used by the strain analyzer to detect strain data in real time. The half-bridge one-to-one compensation and six wire system helps to accurately measure strain data and eliminate the effect of wire impedance on the results. The bridge source voltage and strain gauge resistance values set will affect the sensitivity and measurement range of the instrument. Meanwhile, parameters such as poisson ratio and elastic modulus are helpful for calculating and explaining the strain characteristics of the material.
These parameters are used in strain analyzers to obtain accurate strain data and to help analyze the deformation and strain of the various components of the bucket wheel machine under different conditions, thereby providing the necessary data support for wheel pressure monitoring.
Assuming that the track is a one-dimensional linear elastic track, the elastic material generates forward strain when being subjected to forward stress, which is defined as the ratio of the forward stress to the forward strain:
σ＝E·ε (1)
Wherein E represents the material axial elastic modulus or Young's modulus, sigma represents the forward stress, and epsilon represents the forward strain.
The cross-sectional area of the track under the measuring point is A, the ratio of the force N to the net cross-sectional area A is stress sigma, namely the force born by the unit area is stress; the track stress-strain relationship can be written as formula (2):
The bearing capacity F of the derived track is of formula (3):
F＝A·E·ε (3)
the sticking angle of the strain gauge is miscalculated, and only strain data epsilon 0 inclined relative to the angle theta of the main strain epsilon 1 and transverse strain epsilon 2 are obtained by calculation, so that the formula (4):
The wheel pressure basic database building module is used for receiving the initial data transmitted by the real-time acquisition module; the total force and the whole weight of the whole running system are obtained through data conversion of the initial data, and the wheel pressure condition data of the running wheels and the wheel sets are determined; calculating wheel pressure limit data of the running wheel through materials and structures selected when the bucket wheel machine is designed, and transmitting the wheel pressure limit data to a wheel pressure monitoring module; storing initial data, wheel pressure condition data and wheel pressure limit data into a database, and establishing a wheel pressure basic database of the bucket wheel machine under any working condition; in the module, transmitting initial data and wheel pressure limit data to a comparison analysis module; and simulating the wheel pressure change condition of the bucket wheel machine under various working conditions through finite ternary modeling and SOLIWORKS three-dimensional modeling, and storing the wheel pressure change condition in a database. The wheel pressure basic database established by the invention contains data with infinite possibility of refinement, addition and optimization. In order to ensure the selectivity and accuracy of the data, the wheel pressure basic database preliminarily adopts the pitch angle and the rotation angle of the whole digits and the wheel pressure data of the last digit of the decimal point as the data basis. This data transfer operation ensures that the wheel pressure monitoring module is able to obtain initial data from the road wheel. Meanwhile, the contrast analysis module can receive and analyze the differences between the initial data and the real-time data to determine the current working state of the bucket wheel machine. The combination of data transmission and comparative analysis enables the system to monitor and analyze the state of the running wheel in real time, so that the running condition of the bucket wheel machine can be better known, and powerful support is provided for running optimization and fault diagnosis.
The wheel pressure monitoring module is used for converting the real-time wheel pressure data received from the strain detection module into a waveform chart which is displayed in real time; and comparing the waveform data in the waveform diagram with the wheel pressure limit data, and triggering an alarm when the wheel pressure limit data is exceeded.
The comparison analysis module is used for comparing and analyzing the gesture data received from the strain detection module with the initial gesture data transmitted from the wheel pressure basic database building module so as to determine the current working state of the bucket wheel machine; extracting initial wheel pressure data of the bucket wheel machine with the determined working state in a wheel pressure basic database building module; setting initial wheel pressure data in a wheel pressure basic database building module as lower limit, setting wheel pressure limit data as upper limit, comparing the upper limit and the lower limit with extracted wheel pressure data, and defining the wheel pressure data at the moment as normal wheel pressure data under normal working conditions if the extracted wheel pressure data fall in the interval; and calculating and comparing the normal wheel pressure data with the initial wheel pressure data to obtain the wheel pressure condition, the gravity center offset position data and the overall stability data of the bucket wheel machine running system, and transmitting the result to a display module, wherein the wheel pressure condition comprises: the wheel pressure of each wheel set, the wheel pressure of each running wheel and the gravity center position.
The display module is used for displaying the wheel pressure condition, the gravity center offset position data and the whole stability data of the bucket wheel machine running system received from the comparison analysis module on a display screen, and the display module serves as an interface for information presentation, so that a user can intuitively know the running state and key data of the bucket wheel machine.
It will be appreciated by those skilled in the art in light of the present teachings that various modifications and alterations can be made in light of the above teachings without departing from the scope of the invention and still fall within the scope thereof.
Claims (6)
1. The system is characterized by comprising a real-time acquisition module, a strain detection module, a wheel pressure basic database building module, a wheel pressure monitoring module, a comparison analysis module and a display module;
The real-time acquisition module is responsible for acquiring weight data of all parts of the bucket wheel machine before assembly in real time, acquiring overall weight data and load condition data again after hoisting and assembling, and transmitting initial data to the wheel pressure database building module respectively according to running wheel pressure, pitching and rotating device posture data of the bucket wheel machine under different working conditions; the module is also used for collecting real-time wheel pressure data of each supporting leg in the bucket wheel machine running system to be detected and transmitting the real-time wheel pressure data to the strain detection module;
The strain detection module is used for analyzing the real-time wheel pressure data received from the real-time acquisition module by utilizing a strain detection technology to acquire strain data of a running wheel track when each component forming the bucket wheel machine is assembled; calculating the strain data to obtain real-time wheel pressure data of the newly assembled bucket wheel machine, and transmitting the real-time wheel pressure data to a wheel pressure monitoring module; the attitude data of the bucket wheel machine can be accurately judged by utilizing the strain detection technology and combining with the signal feedback of the original equipment on the bucket wheel machine, and the attitude data is transmitted to the comparison analysis module;
The wheel pressure basic database building module is used for receiving the initial data transmitted by the real-time acquisition module; the total force and the whole weight of the whole running system are obtained through data conversion of the initial data, and the wheel pressure condition data of the running wheels and the wheel sets are determined; calculating wheel pressure limit data of the running wheel through materials and structures selected when the bucket wheel machine is designed, and transmitting the wheel pressure limit data to a wheel pressure monitoring module; storing initial data, wheel pressure condition data and wheel pressure limit data into a database, and establishing a wheel pressure basic database of the bucket wheel machine under any working condition; in the module, transmitting initial data and wheel pressure limit data to a comparison analysis module;
The wheel pressure monitoring module is used for converting the real-time wheel pressure data received from the strain detection module into a waveform chart which is displayed in real time; and comparing the waveform data in the waveform diagram with the wheel pressure limit data received from the wheel pressure basic database building module, and triggering an alarm when the waveform data exceeds the wheel pressure limit data.
The comparison analysis module is used for comparing and analyzing the gesture data received from the strain detection module with the initial gesture data received from the wheel pressure basic database building module so as to determine the current working state of the bucket wheel machine; extracting initial wheel pressure data of the bucket wheel machine with the determined working state in a wheel pressure basic database building module; setting initial wheel pressure data in a wheel pressure basic database building module as lower limit, setting wheel pressure limit data as upper limit, comparing the upper limit and the lower limit with extracted wheel pressure data, and defining the wheel pressure data at the moment as normal wheel pressure data under normal working conditions if the extracted wheel pressure data falls in the interval; calculating and comparing the normal wheel pressure data with the initial wheel pressure data to obtain wheel pressure conditions, gravity center offset position data and overall stability data of the bucket wheel machine running system, and transmitting the results to a display module;
the display module is used for displaying the wheel pressure condition, the gravity center offset position data and the overall stability data of the bucket wheel machine running system received from the comparison analysis module.
2. The bucket wheel travel wheel pressure monitoring and display system of claim 1, wherein the initial data in the real-time acquisition module comprises initial weight, overall weight, load conditions, initial wheel pressure, and initial attitude data.
3. The bucket wheel travel wheel pressure monitoring and display system of claim 1, wherein the attitude data in the strain detection module comprises: pitch angle data and roll angle data.
4. The bucket wheel machine running wheel pressure monitoring and displaying system according to claim 1, wherein the wheel pressure basic database building module further simulates the wheel pressure change condition of the bucket wheel machine under various working conditions through finite ternary modeling and SOLIWORKS three-dimensional modeling, and the wheel pressure change condition is stored in the database.
5. The bucket wheel travel wheel pressure monitoring and display system of claim 1 wherein the wheel pressure condition in the contrast analysis module comprises: the wheel pressure of each wheel set, the wheel pressure of each running wheel and the gravity center position.
6. The bucket wheel machine running wheel pressure monitoring and display system of claim 1, wherein the working conditions mentioned in the real-time acquisition module are: (1) in the material taking state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; (2) in a stacking state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; (3) in the no-load state: the cantilever crane is arranged at the lowest point position of the cantilever crane downward depression, the horizontal position of the cantilever crane and the highest point position of the cantilever crane upward elevation; in addition, the pitching angle of the bucket wheel machine pitching device can work between-16 degrees and +16 degrees, and the turning device angle is between-110 degrees and +110 degrees.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202410066110.1A CN117890006A (en) | 2024-01-17 | 2024-01-17 | Bucket wheel machine walking wheel pressure monitoring and display system |
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| CN202410066110.1A CN117890006A (en) | 2024-01-17 | 2024-01-17 | Bucket wheel machine walking wheel pressure monitoring and display system |
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| CN117890006A true CN117890006A (en) | 2024-04-16 |
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| CN202410066110.1A Pending CN117890006A (en) | 2024-01-17 | 2024-01-17 | Bucket wheel machine walking wheel pressure monitoring and display system |
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