JP6286515B2 - Winding machine life calculator - Google Patents

Description

  The present invention relates to a hoisting machine life calculation apparatus.

  As background art of this technical field, there is JP 2010-180001 (Patent Document 1). This publication states that “a crane operation status management device capable of obtaining information necessary for accurately estimating the life of a crane according to the operation status in consideration of the load factor, the number of operations and the operation time thereof, and the Provide a crane equipped with. "

JP 2010-180001 A

  Patent Document 1 describes the measurement of the number of operations of the hoisting machine, which is necessary for estimating the life of the hoisting machine. However, in Patent Document 1, “the configuration that counts both the number of times of ground cutting and the number of times of upper movement” does not count the number of times of lower movement. For this reason, it is impossible to accurately estimate the life of the hoisting machine.

  Moreover, in patent document 1, only the measurement of the frequency | count of operation | movement for every load and driving | running time is measured, and measurement of a rest time is not performed. Therefore, it is impossible to accurately measure the ratio between the operation time and the downtime, that is, the use frequency, which is one of the measurement values for comprehensively determining the life of the hoisting machine.

  In view of the above problems, an object of the present invention is to provide a hoisting machine life calculation device that can accurately estimate the hoisting machine life.

In order to solve the above problems, for example, the configuration described in the claims is adopted.
The present application includes a plurality of means for solving the above-mentioned problems. For example, a hoisting machine life calculation device for calculating the life of a hoisting machine that performs hoisting or lowering operation, Using the current value of the control inverter of the hoisting machine and the number of rotations of the motor, specify the load of the hoisting machine load and the operating time for each load, and the operating time and operating time for each specified load, etc. The life of the hoisting machine is specified using the time of the hoisting machine.
As an example, for example, a hoisting machine that performs hoisting or lowering operation, and using the current value of the control inverter of the hoisting machine and the rotational speed of the motor, The hoisting machine is characterized in that the life of the hoisting machine is specified using the operating load, operating time and other time for each specified load. is there.

ADVANTAGE OF THE INVENTION According to this invention, the winding machine lifetime calculation apparatus which can estimate the lifetime of a winding machine accurately can be provided.
Problems, configurations, and effects other than those described above will be clarified by the following description of embodiments.

It is an example of the block diagram of a hoisting machine lifetime calculation apparatus. It is an example of the perspective view which shows the whole structure of an inverter type crane apparatus. It is an example of the block diagram which shows the structure of the principal part of an inverter type crane apparatus. It is an example of the flowchart which shows the start timing of a process. It is an example of the flowchart explaining the process of a load discrimination | determination part. It is an example of the flowchart explaining the process of an operation time measurement part. It is an example of the flowchart explaining the process of an operation | movement frequency measurement part. It is an example of the flowchart explaining the process of a load time rate measurement part. It is an example of the operating time preservation | save processing method. It is a display example when displaying on a PC or the like. It is a structural example of the display relation of a winding traverse inverter control part. It is an example of a display in the case of making it display with a winding traverse inverter control part. It is an example of the load discriminating value according to output frequency. It is an example of the load discriminating value according to output frequency.

Hereinafter, examples will be described with reference to the drawings.
FIG. 1 is an example of a configuration diagram of a hoisting machine life calculation apparatus. FIG. 2 is a perspective view showing the overall configuration of an inverter crane apparatus in which the hoisting machine life calculation apparatus according to this embodiment is installed, and FIG. 3 is a block diagram showing the configuration of the main part of the inverter crane apparatus.

  First, the outline | summary is demonstrated about the operation | movement relevant to a hoisting machine lifetime calculation apparatus and a hoisting machine using FIG. In accordance with an operation instruction input from the input device, the control unit of the hoisting machine is operated to operate the motor as a driving unit, and is operated to release the brake adjacent to the motor, and the hoisting machine is driven. . Then, data on the operation status of the motor is sent to the control unit, and the control unit performs display control on the display unit, and displays information that lists the operation status corresponding to the operation content. Further, it may be possible to print the list displayed on the display unit.

Next, the whole structure of an inverter type crane apparatus is demonstrated using FIG.
The inverter type crane apparatus 100 includes a crane hook 1, a wire rope 2, a hoisting induction motor 3, a hoisting apparatus 4, a traverse induction motor 5, a traverse apparatus 6, a traverse girder 7, a travel induction motor 8, and a travel apparatus. 9, a traveling girder 10, a hoisting / traverse inverter device (referred to as a main control unit) 11, a hoisting / traverse inverter control unit 12, described later, an operation input device 13, an hoisting inverter 14, described later, and a traversing described later Inverter 15, induction motor brake 16 described later, travel inverter device 17, travel inverter control unit 18 described later, and travel inverter 19 described later.

  The inverter crane apparatus 100 winds and unloads the load attached to the crane hook 1 by the hoisting device 4 provided with the hoisting induction motor 3 to wind and unwind the wire rope 2 in the Z direction (Z direction, −Z direction). (Indicated by arrows.) That is, the load is moved up and down. Further, in the X direction (indicated by arrows in the X direction and the −X direction), the traverse device 6 including the traverse induction motor 5 and the traverse girder 7 are moved in the X direction. Further, in the Y direction (indicated by arrows in the Y direction and the −Y direction), the traveling apparatus 9 including the traveling induction motor 8 and the traveling girder 10 move in the Y direction.

Next, the control configuration of the inverter crane apparatus will be described with reference to FIG.
The hoisting and traverse induction motors 5 and the traverse induction motor 5 are controlled by the hoisting / traversing inverter control unit 12 of FIG. That is, when the operator inputs a predetermined instruction from the operation input device 13, the hoisting / traverse inverter control unit 12 controls the hoisting inverter 14 and the traverse inverter 15, and the hoisting inverter 14 and the traverse inverter 15, the frequency, voltage, and current necessary for control are applied to the hoisting induction motor 3 and the traverse induction motor 5, and simultaneously, the induction motor brake 16 is controlled to be released, so that the load attached to the crane hook 1 falls. Without moving in the Z direction. In the case of the traversing device 6, the hoisting device 4 is moved in the X direction along the traversing girder 7.

  Similarly, when the operator inputs a predetermined instruction from the operation input device 13, the travel induction motor 8 attached to the travel device 9 causes the travel inverter control unit 18 of FIG. 3 stored in the travel inverter device 17 to travel. Winding along the traveling girder 10 by controlling the inverter 19 and applying the frequency, voltage and current necessary for the control from the traveling inverter 19 to the traveling induction motor 8 and simultaneously controlling the opening of the brake 16 for the induction motor. The upper device 4 is moved in the Y direction.

  Further, the winding inverter 14 includes a current measuring unit 20. The current measuring unit 20 measures a current value for driving the hoisting induction motor 3.

  Further, the hoisting / traverse inverter control unit 12 includes a load conversion unit 21. The load converting unit 21 converts the current value data measured by the current measuring unit 20 into load data by a predetermined calculation. That is, the current value for driving the hoisting induction motor 3 changes according to the weight of the load attached to the crane hook 1, and this current value is converted into load data by the load conversion unit 21. By doing so, the load can be measured. For example, if the load increases, the current value for driving the hoisting induction motor 3 increases, and if the load decreases, the current value for driving the hoisting induction motor 3 decreases.

  Further, the hoisting / traverse inverter control unit 12 includes a slip amount measuring unit 22. The slip amount measuring unit 22 converts the signal from the encoder 23 that outputs the rotation state of the hoisting induction motor 3 as a pulse signal into a rotation speed, and calculates the synchronous rotation speed calculated from the operating frequency and the measured actual rotation speed. The amount of slip that is the difference is measured. That is, since the amount of sliding changes according to the weight of the load attached to the crane hook 1, the load can be measured by converting this amount of sliding into load data by the load converting unit 21. . For example, if the load increases, the slip amount of the hoisting induction motor 3 increases, and if the load decreases, the slip amount of the hoisting induction motor 3 decreases.

  Here, in the case of inverter control, there is a case where it is operated at an operating frequency equal to or lower than the rated speed, but in this case, since the amount of change in the current value that changes according to the weight of the load is reduced particularly in the downward direction, Although it is difficult to accurately determine the load, having the load determining means based on the amount of sliding makes it possible to determine the load with high accuracy together with the load determination of the current value.

  The load detected as described above may be used for processing as it is, but the amount of data becomes enormous. Therefore, in this embodiment, with respect to the rated load (100%) of the hoisting machine, there is no load (0%), light load (1-25%), medium load (26-50%), heavy load (51 ˜75%) and super heavy load (76% ˜).

  Needless to say, the relationship between the current value and the load data or the relationship between the slip amount and the load data can be easily determined experimentally in advance or by a predetermined calculation.

  A specific load determination method of the load conversion unit 21 will be described with reference to FIGS. 4 is a flowchart showing the start timing of the load determination process, and FIG. 5 is a flowchart of the load determination process.

  The load determination process is started by, for example, a software interruption process every 100 ms. When the induction motor brake 16 is released (S1), the load determination process is started (S4).

  In the load determination process, when the hoisting machine is accelerating or decelerating, the current value and the amount of slip cannot be measured with high accuracy. Therefore, it is necessary to measure the current value and the amount of slip at a constant speed. Therefore, as shown in FIG. 4, there is an operation instruction in the “up” or “down” direction (S101), and the frequency output by the hoisting inverter 14 to the hoisting induction motor 3 is controlled by the hoisting / traverse inverter control. The target frequency indicated by the unit 12 is compared with the output frequency actually output from the hoisting inverter 14 (S102). If the indicated frequency is the same as the output frequency or the output frequency is greater than the indicated frequency. Since the speed is constant, a current value and a slip amount are acquired (S103).

  If the above condition is not satisfied, the load determination process is returned to the initial state and the process is terminated (S109).

  The current value and the amount of sliding are always detected regardless of the state of the hoisting machine during acceleration or deceleration.

  After acquiring the current value and the amount of slip of the set number of acquisitions (S104) and when the acquisition of the current value and the amount of slip is completed, for example, after storing the acquired values for five times in order to suppress the variation of the acquired values (S110) The average value is calculated (S105).

  When the calculation of the average value of each of the current value and the amount of slip is completed, the counter of the total value of acquisition values and the number of acquisition times is cleared. (S106) The value of the output frequency output from the hoisting inverter 14 is compared with a set reference value (for example, 30 Hz) of the output frequency (S107). Is used as a load determination parameter, and the load class is determined from the average amount of sliding and the operation direction (S108). On the other hand, if the load class is larger than the reference value, the current value is used as the load determination parameter. The load class is determined from (112).

  In addition, since the current value and the amount of sliding change depending on the operation direction (Z direction) of the hoisting machine, it is necessary to determine the operation direction as a load determination parameter. -If the input to the traverse inverter control unit 12 is confirmed, the operation direction can be known.

  Here, depending on the output frequency, either the current value or the slip amount may not be used as the load determination parameter, but both may be used as the load determination parameter.

  When the parameters for determining the load are obtained as described above, the loads are classified into five patterns according to the divisions determined in advance as shown in FIGS. For example, when the current value is detected as 11 A with an output frequency of 60 Hz and an upward operation, the load determination is determined as a medium load (S112).

  Next, the operation time measurement process S5 shown in FIG. 4 will be described. As shown in FIG. 3, the hoisting / traverse inverter control unit 12 includes an operation time measuring unit 24. The operation time measurement unit 24 measures and integrates the release control time of the induction motor brake 16 controlled by the hoisting / traverse inverter control unit 12 to be released. That is, the total operation time is measured.

  Further, the operation time measuring unit 24 measures and integrates the opening control time of the induction motor brake 16 for each load category determined by the load determination process. That is, the operation time for each load category is measured.

  A specific operation time measurement method of the operation time measurement unit 24 will be described with reference to FIGS. FIG. 6 is a flowchart of the operation time measurement process.

  The start of the operation time measurement process is, for example, a software interruption process every 100 ms. When the induction motor brake 16 is released (S1), the operation time measurement process is started after the load determination process (S4) ends (S5). ).

  In the operation time measurement process, every time the process is executed, first, the count of the total operation time is advanced by 1 (S201). Next, the operation time count for each load category is incremented by 1 from the determined load category (S206 to S210). As described above, the total operation time and the operation time for each load category can be measured.

  Needless to say, the conversion to the actual operation time with respect to the accumulated number of operation times is determined by the execution interval of the operation time measurement process.

  Next, the operation number measurement process S6 shown in FIG. 4 will be described. As shown in FIG. 3, the hoisting / traversing inverter control unit 12 includes an operation frequency measuring unit 25. The number-of-operations measurement unit 25 controls the release of the induction motor brake 16 controlled by the hoisting and traverse inverter control unit 12 and then returns to the original number for each load category determined by the load determination process. Is accumulated. That is, the number of operations for each load category is measured.

  A specific operation frequency measuring method of the operation frequency measuring unit 25 will be described with reference to FIGS. FIG. 7 is a flowchart of the operation count measurement process.

  As shown in FIG. 4, the operation frequency measurement process is started by, for example, a software interrupt process every 100 ms. When the induction motor brake 16 is released, the brake release flag is set to 1 (S2), and the induction motor When the brake 16 is braked, the brake release flag is set to 0 (S3). The operation number measurement process is started after the brake release flag is operated as described above (S6).

  As shown in FIG. 7, every time the operation count measurement process is executed, the state of the brake release flag is confirmed (S301), and the operation state of the brake is also confirmed (S302). If the brake release flag is 1 and the brake is in a braking state, the brake release flag is set to 0 (S303).

  If the brake release flag is set to 0, the total number of operations is incremented by 1 (S304). Next, the count of the number of operations for each load category is incremented by 1 from the determined load category (S306 to S310). As described above, the total number of operations and the number of operations for each load category can be measured.

  Next, the load time rate measurement process S7 shown in FIG. 4 will be described. First, calculation of the remaining life will be described. As shown in FIG. 3, the hoisting / traverse inverter control unit 12 includes a remaining life calculating unit 26 in order to calculate the remaining life of the hoisting machine. The remaining life calculation unit 26 calculates the remaining life from the operation time for each load category detected as described above.

  A specific method for calculating the remaining life of the hoisting machine performed by the remaining life calculating unit 26 will be described. The remaining life of the hoisting machine is first calculated based on [Equation 1].

The values measured in the above are used for the operation time and the total operation time for each load category in [Expression 1], and the values described in FIGS.

Next, the load factor calculated by [Equation 1] is divided by the load factor 0.63 when a hoist is generally used, and the valence load factor is calculated from (Equation 2).

(Equation 2)
Equivalent load factor = (Load factor / 0.63) ³

Next, the value operation time is calculated from (Equation 3). Here, the value measured as described above is used as the total operation time.

(Equation 3)
Equivalent operation time = Total operation time x Equivalent load factor

When the equivalent operation time and the equivalent load factor are found from the above, the remaining life is calculated by (Equation 4).

(Equation 4)
Remaining life = set total operation time x equivalent operation time

Since the set total operation time of (Equation 4) can be determined from the specifications of the hoisting machine, an initial value may be set in the remaining life calculation unit 26. Further, the set total operation time may be changed later.

  Here, although the remaining life is found from the above, in order to comprehensively determine the remaining life of the hoisting machine, the ratio of the downtime and the operating time of the hoisting machine, that is, the load time rate is required. This is because when the hoisting machine is operated intensively in a short time, a load is applied to the hoisting induction motor 3 and the hoisting inverter 14.

  In order to measure the load time rate, the hoisting / traverse inverter control unit 12 includes a load time rate measuring unit 27. The load time rate measuring unit 27 calculates the load time rate by determining the operation time and the downtime by measuring the release control time of the brake 16 for the induction motor that is controlled to be released by the hoisting / traverse inverter control unit 12. To do.

  A specific method for measuring the load time rate will be described with reference to FIGS. FIG. 8 is a flowchart of the load time rate measurement process.

  First, general calculation of the load time rate will be described. The load time rate is expressed by the unit% ED, indicating how many minutes the operation is performed during 60 minutes. Since the operation time can be measured by confirming the operation state of the induction motor brake 16, the downtime can also be measured by confirming the operation state of the induction motor brake 16.

  As shown in FIG. 4, the load time rate is measured by software interrupt processing every 100 ms, for example, and the load time rate measurement processing is always performed regardless of the state of the induction motor brake 16 (S7).

  In the load time rate measurement process, each time the process is executed, first, the operating state of the induction motor brake 16 is checked to determine whether it is operating or stopped (S401). If it is in operation, 100 ms is added to the cumulative operation time (S402).

  Next, it is confirmed whether the sum of the accumulated operation time and the accumulated stop time is 1 minute or more (S403). If it is less than 1 minute, the interrupt processing for measuring the load time ratio is terminated. In the case of 1 minute or more, an operation time storage process (S404) is performed.

  Here, the operation time storage process (S404) will be described with reference to FIG. In the operation time storage process (S404), for example, the past 60 operation times for one minute, that is, the operation time for the past 60 minutes can be stored in the storage unit 28 of the hoisting and traverse inverter control unit 12 for 60 storages. An area is provided ([1]). For example, the storage area is defined as area 1 for storing the latest operation time, area 2 for storing the next new operation time, and area 60 for storing the oldest operation time in the following order.

  Next, each time the operation time storage process (S404) is executed, the oldest data stored in the area is deleted ([2]). The oldest data is determined when 60 areas are stored in the storage unit. For example, the address of area 1 is 001, the address of area 2 is 002,... An address is automatically assigned. Since these addresses are continuous, the oldest data can be determined by checking the addresses.

  Next, the process of moving the data in the area 59 to the area 60 and further moving the data in the area 58 to the area 59 is repeated until the data in the area 1 is moved to the data 2 ([3]).

  Next, by storing the latest operation time in the region 1 ([4]), the operation time for the past 60 minutes can be stored.

  When the operation time storage process (S404) is completed, the operation time accumulation and the stop time accumulation are cleared (S405). By clearing, the next one-minute operation time can be measured.

  Next, the load time rate for 15 minutes is calculated (S406). The calculation method is to calculate the load time ratio for 15 minutes by adding the operation time for 15 minutes from the latest data stored in the operation time storage process (S404) and dividing the total operation time by 15 minutes. Can do. Here, the calculated load time rate for 15 minutes may be compared with the previously calculated load time rate for 15 minutes, and the larger one may be stored as the maximum value.

  Next, the load time rate for 30 minutes (S407), the load time rate for 45 minutes (S408), and the load time rate for 60 minutes (S409) are calculated, and the load time rate measurement process ends. The method of the load time rate calculation process at each time interval is the same as the load time rate calculation process for 15 minutes, and it goes without saying that each time. Further, it goes without saying that changes such as increasing or shortening each time interval of the load time rate calculation process are easy.

  As described above, if the measured or calculated data is erased every time the power is turned off, it is meaningless because the data cannot be accumulated. Therefore, it is necessary to store the data so that it is not erased when the power is cut off.

  As a storing method, the data is stored in the storage unit 28 in the hoisting / traverse inverter control unit 12. Further, it may be stored in an external storage device such as a hard disk or USB. As described above, as a format for outputting measured or calculated data, for example, if a diagram such as FIG. 10 is displayed by connecting to a PC, the measured and calculated data can be understood at a glance, and the remaining life of the hoisting machine can be comprehensively determined. It is easy to judge.

  Moreover, you may display the data measured and calculated with the digital display mounted in the control part of a general inverter type crane apparatus. In this embodiment, a method for displaying measured or calculated data on a digital display will be described with reference to FIGS.

  In order to display the measured and calculated data, as shown in FIG. 11, a 7-segment LED display 29 which is a digital display capable of displaying characters on the hoisting and traverse inverter control unit 12 and a display for operating the display. Four switches 30 are provided.

  FIG. 12 shows an example of a display configuration of measured and calculated data displayed on the 7-segment LED display 29 and an operation method for displaying the data.

  For example, when the operation time is desired to be displayed, since the initial display is the number of operations, the down arrow switch is operated to select the operation time. After selecting the operating time, operating the right arrow switch displays the total operating time. Next, when the down arrow switch is operated, the no-load operation time is displayed. If the down arrow switch or the up arrow switch is operated below, the total operation time and the operation time for each load category can be displayed.

  According to the present embodiment, the remaining life of the hoisting machine can be displayed, and by measuring the operation status including the downtime, the load time rate of the hoisting machine, that is, the usage frequency can be accurately measured and displayed. It is possible to provide a hoisting machine life calculation device that can be used.

  Furthermore, since the total number of operations, the number of operations for each load, the total operation time, and the operation time for each load can be measured and displayed, it is possible to provide a judgment material for estimating the life of the hoisting machine.

1: Crane hook 2: Wire rope 3: Hoisting induction motor 4: Hoisting device 5: Traverse induction motor 6: Traverse device 7: Traverse girder 8: Traveling induction motor 9: Traveling device 10: Traveling girder 11: Hoisting and traverse inverter device 12: Hoisting and traverse inverter control unit 13: Operation input device 14: Hoisting inverter 15: Traverse inverter 16: Induction motor brake 17: Traveling inverter device 18: Traveling inverter control Unit 19: Traveling inverter 20: Current measuring unit 21: Load converting unit 22: Sliding amount measuring unit 23: Encoder 24: Operating time measuring unit 25: Operation frequency measuring unit 26: Remaining life calculating unit 27: Load time rate measuring unit 28: Storage unit 29: 7 segment LED
30: Operation switch

Claims (10)

A hoisting machine life calculation device for calculating the life of a hoisting machine that performs hoisting or lowering operation,
Using the current value of the control inverter of the hoisting machine and the rotation speed of the motor, the load of the hoisting load of the hoisting machine and the operation time for each load are specified,
A hoisting machine life calculation device characterized in that a load factor is obtained using the specified operation time , total operation time and load ratio for each load, and the life of the hoisting machine is specified based on the load factor. . The hoisting machine life calculation apparatus according to claim 1,
The determination of the load is specified from the current value and the operating direction of the hoisting machine, wherein the hoisting machine life calculation device is characterized. The hoisting machine life calculation apparatus according to claim 1,
Particular the lifetime, obtains the equivalent load factor, using the load factor, the hoisting machine life calculation apparatus characterized by determined based on the equivalent operation time determined using the total operation time and the equivalent load factor . The hoisting machine life calculation apparatus according to claim 1,
A hoisting machine life calculation apparatus comprising a display unit for displaying an operation time for each load. The hoisting machine life calculation apparatus according to claim 3,
It has a display unit for displaying at least one of the remaining life, total operation time , total operation number, operation number by load, total operation time, operation time by load, and load time rate of the hoisting machine. Winder life calculator. A hoisting machine that performs hoisting or lowering operation,
Using the current value of the control inverter of the hoisting machine and the rotation speed of the motor, the load of the hoisting load of the hoisting machine and the operation time for each load are specified,
A hoisting machine characterized in that a load factor is obtained using the specified operating time , total operating time and load ratio for each load, and the life of the hoisting machine is specified based on the load factor . The hoist according to claim 6,
The determination of the load is specified from the current value and the operating direction of the hoisting machine. The hoist according to claim 6,
Particular the lifetime, obtains the equivalent load factor, using the load factor, hoist, characterized in that it is determined based on the equivalent operation time determined using said equivalent load ratio the total operating time. The hoist according to claim 6,
A hoisting machine life calculation apparatus comprising a display unit for displaying an operation time for each load. The hoist according to claim 8,
It has a display unit for displaying at least one of the remaining life, total operation time , total operation number, operation number by load, total operation time, operation time by load, and load time rate of the hoisting machine. A hoisting machine.

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