WO2013086942A1 - 臂架振动监测的车载数据单元、方法、工程机械及系统 - Google Patents

臂架振动监测的车载数据单元、方法、工程机械及系统 Download PDF

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Publication number
WO2013086942A1
WO2013086942A1 PCT/CN2012/085976 CN2012085976W WO2013086942A1 WO 2013086942 A1 WO2013086942 A1 WO 2013086942A1 CN 2012085976 W CN2012085976 W CN 2012085976W WO 2013086942 A1 WO2013086942 A1 WO 2013086942A1
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WO
WIPO (PCT)
Prior art keywords
vibration
data
signal
boom
time
Prior art date
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Ceased
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PCT/CN2012/085976
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English (en)
French (fr)
Inventor
黄毅
邝昊
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Zoomlion Heavy Industry Science and Technology Co Ltd
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Zoomlion Heavy Industry Science and Technology Co Ltd
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Publication of WO2013086942A1 publication Critical patent/WO2013086942A1/zh
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Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01HMEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H1/00Measuring characteristics of vibrations in solids by using direct conduction to the detector
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00Other constructional features or details
    • B66C13/04Auxiliary devices for controlling movements of suspended loads, or preventing cable slack
    • B66C13/06Auxiliary devices for controlling movements of suspended loads, or preventing cable slack for minimising or preventing longitudinal or transverse swinging of loads
    • B66C13/066Auxiliary devices for controlling movements of suspended loads, or preventing cable slack for minimising or preventing longitudinal or transverse swinging of loads for minimising vibration of a boom
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02Conveying or working-up concrete or similar masses able to be heaped or cast
    • E04G21/04Devices for both conveying and distributing
    • E04G21/0418Devices for both conveying and distributing with distribution hose
    • E04G21/0436Devices for both conveying and distributing with distribution hose on a mobile support, e.g. truck
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02Conveying or working-up concrete or similar masses able to be heaped or cast
    • E04G21/04Devices for both conveying and distributing
    • E04G21/0418Devices for both conveying and distributing with distribution hose
    • E04G21/0445Devices for both conveying and distributing with distribution hose with booms
    • E04G21/0454Devices for both conveying and distributing with distribution hose with booms with boom vibration damper mechanisms

Definitions

  • Vehicle data unit Vehicle data unit, method, engineering machine and system for boom vibration monitoring
  • the present invention relates to the field of construction machinery, and in particular to a vehicle data unit, a method for boom vibration monitoring, and a construction machine and system including the onboard data unit. Background technique
  • Concrete pump truck is a kind of construction machinery that uses pressure to continuously transport concrete along pipelines. It is widely used in various fields such as road engineering, bridge engineering, underground engineering, industrial and civil construction. With the rapid development of pump trucks, the vibration performance of the pump boom has received more and more attention. Therefore, the monitoring of the vibration state of the pump boom produced and the collection and analysis of vibration data are the basis for quickly dealing with on-site vibration problems, improving the image of the company's service, improving the vibration quality of the product, and providing the necessary performance for improving the product. Indispensable data support.
  • the object of the present invention is to provide an onboard data unit for boom vibration monitoring, a method for boom vibration monitoring, and a concrete including the vehicle data unit, in view of the defects in the prior art that the vibration data cannot be saved in time. Pump trucks and systems.
  • the present invention provides an in-vehicle data unit for vibration monitoring of a boom, comprising: a vibration detecting device for detecting the vibration of the boom in real time and outputting the vibration of the boom. a vibration signal; a controller, configured to receive a vibration signal output by the vibration detecting device to generate vibration data, and compare the vibration intensity obtained according to the vibration signal with a preset vibration trigger threshold, when the vibration intensity exceeds the vibration trigger threshold Transmitting the vibration data to the memory; and storing the received vibration data.
  • the present invention also provides a construction machine having a boom comprising the above-described onboard data unit for boom vibration monitoring.
  • the invention further provides a method for monitoring vibration of a boom, wherein the method comprises the steps of: detecting the vibration of the boom in real time and obtaining a vibration signal characterizing the vibration of the boom; generating vibration data according to the vibration signal, and The vibration intensity obtained by the vibration signal is compared with a preset vibration trigger threshold; and the vibration data is stored when the vibration intensity exceeds the vibration trigger threshold.
  • the present invention also provides a system for monitoring vibration of a boom, comprising: at least one of the above-mentioned onboard data units for monitoring vibration of the boom; and a data master communicating with the onboard data unit for Receiving vibration data from the onboard data unit via a wireless network and uploading it to a remote data center; a remote data center communicating with the data master for receiving vibration data from the data master and receiving the vibration data Analyze.
  • the vehicle data unit is installed on the concrete pump truck, and various parameters in the vibration process of the boom are monitored in real time and recorded, if the vibration problem occurs, the technician can record the scene even if the technician is not at the scene.
  • the vibration data of the first hand will not record the data in time because of the transfer of the pump, and no technician is required to rush to the construction site to collect data.
  • the present invention performs vibration data storage only when the vibration is excessively large, which reduces the number of accesses of the memory and prolongs the life of the hardware.
  • the in-vehicle data unit does not store all of the vibration data, but saves the vibration data closely related to the excessive vibration, so that the storage space required is large compared to the data acquisition without selection. Reduced, the hardware requirements are also greatly reduced.
  • the in-vehicle data unit can also transmit the vibration data to the data main station through the wireless network, and then upload to the remote data center for the sub-network.
  • FIG. 1 is a block diagram showing the structure of an in-vehicle data unit provided in accordance with the present invention
  • FIG. 2 is a structural block diagram of an in-vehicle data unit provided in accordance with a preferred embodiment of the present invention
  • FIG. 3 is a flow chart of a method for boom vibration monitoring provided in accordance with a preferred embodiment of the present invention
  • FIG. 4 is a structural block diagram of a system for boom vibration monitoring provided in accordance with the present invention. Description of the reference numerals
  • the onboard data unit 10 for boom vibration monitoring comprises: a vibration detecting device 1 for detecting boom vibration in real time and outputting a vibration signal characterizing the vibration of the boom;
  • the controller 2 is configured to receive the vibration signal output by the vibration detecting device 1 to generate vibration data, and compare the vibration intensity obtained according to the vibration signal with a preset vibration trigger threshold, and when the vibration intensity exceeds the vibration trigger threshold
  • the vibration data is sent to the memory 3; the memory 3 is used to store the received vibration data.
  • the vibration detecting device 1 is any sensor capable of detecting the vibration of the boom, which is capable of outputting a signal indicative of vibration, referred to herein as a "vibration signal.”
  • the vibration detecting device 1 may be, for example, at least one of a vibration sensor, a displacement sensor, an acceleration sensor, and a speed sensor, wherein, for example, the acceleration sensor or the speed sensor outputs an acceleration or speed signal, but according to the acceleration or speed signal, Vibration displacement, which also characterizes vibration, can also be referred to as a vibration signal.
  • the vibration detecting device 1 may have a plurality of positions at different positions of the boom to detect vibrations at different positions of the boom.
  • the onboard data unit 10 may further include a hydraulic pressure detecting device 4 for detecting the pressure of the hydraulic system and outputting the hydraulic pressure signal.
  • the hydraulic system may include a main pump and each arm cylinder, and the detected pressure may also be a main pump pressure, a rod chamber of each arm cylinder, and a pressure of a rodless chamber.
  • the hydraulic pressure detecting device 4 may be a pressure sensor, and may have a plurality of them.
  • the in-vehicle data unit 10 may further include a boom attitude detecting device 6 for detecting the current posture of the boom in real time and outputting an attitude signal.
  • the boom attitude detecting device 6 can be a tilt sensor. By installing a tilt sensor on each arm joint, the tilt angle of each arm joint and the horizontal plane can be measured, and the posture of the current boom can be determined, and the attitude signal can be an inclination signal.
  • the onboard data unit 10 can also monitor electrical signals and operation command signals and the like inside the pump truck to synchronously record the operating environment of the pump truck, due to electrical signals or operation command signals.
  • the body is an electrical signal, so it can be detected without using a detecting device such as a sensor, but the controller 2 can directly obtain various electrical signals, as shown in FIG.
  • the controller 2 is configured to receive the vibration signal, and in the preferred case, receive a hydraulic signal, an attitude signal, an electrical signal, and/or an operational command signal to generate vibration data for data storage.
  • the vibration data is preferably established in a two-layer linked list, including a header and a data field, wherein the header includes at least one of a pump model, a channel number, an acquisition date, a time, a sampling frequency, a data length, and a data field file name. And at least the vibration signal (preferably including the hydraulic signal, etc.) is stored in the data field, and the file name of the preferred data field is used as a field in the header, which can be easily retrieved and called.
  • Each channel uses a header, and the record is additionally saved according to the channel number, so that the number of bytes in the header is greatly reduced, and the positioning, retrieval, invocation, and copying of the data record are very convenient and rapid.
  • the controller 2 also calculates the vibration intensity based on the received vibration signal.
  • the vibration intensity is a parameter reflecting the vibration intensity, which may be the maximum value, the average value, the effective value or the root mean square value of the vibration amplitude, etc., and those of ordinary skill in the art may adopt different calculations depending on which vibration detecting device 1 is used.
  • the vibration intensity can be obtained from the vibration signal, so the calculation process will not be described in detail here.
  • the controller 2 compares the calculated vibration intensity with a preset vibration trigger threshold to determine whether the condition for storing the data is satisfied, and the controller 2 transmits the vibration data to the memory only when the vibration intensity exceeds the vibration trigger threshold. 3 for storage. This is because vibration signals are always generated during the operation of the pump truck. If the vibration data is continuously recorded, continuous access to the memory 3 will affect the life of the hardware. However, if the data storage strategy of the present invention is used, the vibration data storage is performed only when the vibration is excessively large, the number of accesses is reduced, and the hardware life is prolonged.
  • the vibration trigger threshold is preset, and can also be adjusted at any time.
  • the selection of the value is related to the safety vibration intensity of the boom, and generally does not exceed the safety vibration intensity.
  • the so-called safety vibration intensity is that the boom does not cause safety problems when it vibrates within the range of this safe vibration intensity.
  • the controller 2 Before the controller 2 transmits the vibration data, the controller 2 stores the generated vibration data in a slow manner.
  • the cache space may be the memory of the controller 2 or a part of the storage space of the memory 3. Subsequently, the controller 2 transmits the vibration data in the buffer space to the memory 3 for storage in the case where the trigger condition is satisfied, that is, the vibration intensity exceeds the vibration trigger threshold.
  • the vibration data stored here may be all vibration data generated during the monitoring, including vibration data before the vibration intensity exceeds the vibration trigger threshold and vibration data generated thereafter.
  • this method will have a very large amount of storage, requires a large storage space, and is difficult to manage due to too much data, and is generally less used.
  • the controller 2 sends the current vibration data when the vibration intensity exceeds the vibration trigger threshold, or the current vibration data and the vibration data generated thereafter, or the current vibration data and the vibration data generated after a period of time to Memory 3.
  • This method reduces the amount of storage. On the one hand, it saves storage space relative to all storage.
  • the stored data is valuable data for later analysis, which is easy to manage and has high recording efficiency.
  • this method does not preserve the vibration data before the vibration intensity is too large. The lack of this data is not conducive to the excessive vibration caused by the later analysis.
  • the controller 2 transmits the vibration data generated for a period of time from the time before the time when the vibration intensity exceeds the vibration trigger threshold to the memory 3. This method not only saves storage space, but also saves the vibration data of the entire vibration process, which is convenient for statistical analysis.
  • the second scenario described above uses the first-in-first-out data storage method of the cache space. That is to say, the latest addition to the cache space is the vibration data generated at the current time, and the cache space only stores a continuous piece of data, and the previous data can be give up.
  • the controller 2 is configured to transmit the vibration data generated between the time t r T and the time t 2 +T to the memory 3, where ⁇ is the time when the vibration intensity exceeds the vibration trigger threshold, and t 2 is the vibration after again the vibration intensity is smaller than the trigger threshold time, a time period T is redundant, in the range of T 0 ⁇ T ⁇ T max, the maximum continuous period of time T max is the vibration data can be stored in the cache space.
  • T can be 0, and the range of storage at this time Between ⁇ and ⁇ , the entire process of the vibration intensity super-vibration trigger threshold is recorded, but in order to analyze the vibration process before and after, it is preferable that T is greater than 0 to include the entire development process.
  • the maximum continuous time period Tmax of the vibration data that can be stored in the buffer space depends on the size of the buffer space, the frequency of generation of the vibration data, and the magnitude of the vibration data generated each time. For example, Tmax can be calculated according to the following formula :
  • T max size of the buffer space / (frequency of generation of vibration data * average size of vibration data generated each time).
  • the specific implementation process of the above preferred embodiment is as follows: at the moment when the vibration intensity exceeds the vibration trigger threshold, that is, the current time, and traces back to t r T, the buffer space t r T to the time The generated vibration data is transferred to the memory 3. If ⁇ 1 ⁇ , it only goes back to time 0, which is the starting time. Further, since the period before time t r T, the vibration intensity exceeds the threshold value triggering the vibration does not appear at this time may be vibration data buffer space in time t r T before deleted. At this time, the vibration continues, and the vibration data is continuously transferred until the vibration intensity is again smaller than the vibration trigger threshold at time t 2 , which means that the vibration returns to the normal state, and it is only necessary to retain the ⁇ time on this basis.
  • the vibration data in the segment can be used.
  • the vibration intensity exceeds the vibration trigger threshold again within the time period of t 2 +T (this time can be regarded as new)
  • the time to + D is definitely to the new t 2 '+T
  • the data to +1 is also dumped, and the above technical solution is also satisfied.
  • the memory 3 is a general data storage device that can be integrated in the controller 2 or can be an external memory.
  • the in-vehicle data unit 10 further includes a wireless transceiver 5 for transmitting the vibration data stored in the memory 3 through the wireless network.
  • the wireless transceiver 5 can be a digital transceiver using various wireless communication protocols, such as radio frequency, GSM, GPRS, CDMA wireless transceivers, and the like.
  • the invention also provides a construction machine with a boom, the above-mentioned vehicle data unit 10 is mounted on The construction machine is used for real-time monitoring of the vibration of the boom of the construction machine and recording data. In this way, if a vibration problem occurs, even if the technician is not at the scene, the first-hand vibration data of the site can be recorded, and the data cannot be recorded in time due to the transfer of the pump truck.
  • the present invention is illustrated with a concrete pump truck as an example, those skilled in the art will appreciate that the in-vehicle data unit provided by the present invention and the system described below can be used with all construction machines having a boom.
  • the vibration data is stored when the vibration intensity exceeds the vibration trigger threshold.
  • FIG. 3 is a preferred embodiment of the present invention, and the method provided by the present invention will be described below with reference to FIG.
  • the dashed box indicates the preferred step and is not a necessary step.
  • the pressure of the hydraulic system can be detected in real time and the hydraulic signal can be obtained, and the posture of the boom can be detected in real time and the attitude signal can be obtained.
  • Electrical signals and/or operational command signals can be obtained.
  • the vibration data can be generated based on at least one of a hydraulic pressure signal, an attitude signal, an electrical signal, and an operation command signal, and a vibration signal.
  • the vibration data is preferably established in the manner of the above-mentioned two-layer linked list, including a header and a data field, wherein the header includes a pump model, a channel number, an acquisition date, a time, a sampling frequency, a data length, and a data.
  • the field file name and the like, and the vibration signal, the hydraulic signal, and the like are stored in the data field, and the file name of the data field is used as a field in the header.
  • the method further comprises: transmitting the stored vibration data (not shown) through the wireless network.
  • the present invention further provides a system for monitoring vibration of a boom, wherein the system comprises: at least one vibration monitoring for the boom provided by a preferred embodiment of the present invention In-vehicle data unit 10 (including a wireless transceiver); data master station 30, in communication with the in-vehicle data unit 10, for receiving vibration data from the in-vehicle data unit 10 via the wireless network 20 and uploading it to remote data The center 40; the remote data center 40, in communication with the data master station 30, receives vibration data from the data master station 30 and analyzes the received vibration data.
  • In-vehicle data unit 10 including a wireless transceiver
  • data master station 30 in communication with the in-vehicle data unit 10, for receiving vibration data from the in-vehicle data unit 10 via the wireless network 20 and uploading it to remote data
  • the center 40 the remote data center 40, in communication with the data master station 30, receives vibration data from the data master station 30 and analyzes the received vibration data.
  • the data master station 30 is installed at the technical service station to which the pump truck to be monitored belongs, and a technical service station can monitor multiple pump trucks within a certain geographical range (the range covered by the wireless transmission).
  • the data master station 30 mainly plays the role of summarizing and relaying the vibration data. Therefore, the data master station 30 mainly includes a server, and has the functions of wireless reception, data summary storage, and data transmission, which can be realized by a conventional server.
  • the data master station 30 can adopt various uploading methods such as periodic uploading, request uploading by the remote data center 40, and request uploading by the in-vehicle data unit 10.
  • the data master station 30 can also have multiple, dispersed in different areas.
  • the remote data center 40 is installed in the technical research and development department of the manufacturing enterprise. Because the construction location of the pump truck and the manufacturing enterprise may be far apart, it is not convenient to directly transmit data through the wireless network, so the vibration data is first transmitted by wireless transmission. To the data master station 30, the data master station 30 then forwards the data to the remote data center 40 over the wired communication network.
  • the remote data center 40 includes a remote vibration database and a WEB server, and the vibration data from the data master is input to the remote vibration database through the WEB server for analysis. Through this communication mode, the monitoring and monitoring of the vibration performance of the pump truck can be realized remotely, and the technician does not have to visit the scene. It is possible to grasp the data on the spot, and it is beneficial for after-sales service maintenance, monitoring of boom vibration performance, and product improvement.

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  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
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Abstract

一种用于臂架振动监测的车载数据单元(10),包括:振动检测装置(1),用于实时检测臂架振动并输出表征臂架振动的振动信号;控制器(2),用于接收所述振动检测装置(1)输出的振动信号以生成振动数据,并将根据振动信号得到的振动烈度与预设的振动触发阈值进行比较,当振动烈度超过该振动触发阈值时将振动数据发送到存储器(3);存储器(3),用于存储接收到的所述振动数据。这样,如果发生振动问题,即使技术人员不在现场,也能记录现场第一手的振动数据,不会因为泵车的转移而未能及时记录数据。并且仅在振动过大时才进行振动数据存储,降低了存储器的存取次数,延长了硬件寿命。还提供了用于臂架振动监测的方法、工程机械以及系统。

Description

臂架振动监测的车载数据单元、 方法、 工程机械及系统 技术领域
本发明涉及工程机械领域, 具体地, 涉及一种用于臂架振动监测的车 载数据单元、 方法以及包括该车载数据单元的工程机械及系统。 背景技术
混凝土泵车是一种利用压力将混凝土沿管道连续输送的工程机械, 其 广泛应用于道路工程、 桥梁工程、 地下工程、 工业与民用建筑施工等各个 领域。 随着泵车的飞速发展, 泵车臂架的振动性能越来越受到重视。 因此, 实现对所生产的泵车臂架振动状态的监测以及对振动数据的采集、 分析是 快速处理现场振动问题、 提升企业服务形象、 提高产品振动品质的基础, 也提供了改进产品性能所必不可少的数据支持。
现有技术中均是技术人员到现场采集振动数据。 然而, 由于泵车数量 较多, 施工作业位置也不固定, 经常在郊区甚至野外作业, 这都给振动数 据的采集带来诸多不便。 例如, 当泵车臂架出现振动问题时, 等到技术人 员赶到现场的时候, 泵车往往因为施工进度的要求而转移了施工场地, 这 样, 一些关键的振动数据并没有得到及时保存。 发明内容
本发明的目的是针对现有技术中不能及时保存振动数据的缺陷, 提供 一种用于臂架振动监测的车载数据单元、 一种用于臂架振动监测的方法以 及包括该车载数据单元的混凝土泵车及系统。
为了实现上述目的, 本发明提供一种用于臂架振动监测的车载数据单 元, 包括: 振动检测装置, 用于实时检测臂架振动并输出表征臂架振动的 振动信号; 控制器, 用于接收所述振动检测装置输出的振动信号以生成振 动数据, 并将根据振动信号得到振动烈度与预设的振动触发阈值进行比较, 当振动烈度超过该振动触发阈值时将振动数据发送到存储器; 存储器, 用 于存储接收到的所述振动数据。
本发明还提供一种具有臂架的工程机械, 包括上述用于臂架振动监测 的车载数据单元。
本发明又提供一种用于臂架振动监测的方法, 其中, 该方法包括以下 步骤: 实时检测臂架振动并得到表征臂架振动的振动信号; 根据所述振动 信号生成振动数据, 并将根据振动信号得到的振动烈度与预设的振动触发 阈值进行比较; 以及当振动烈度超过该振动触发阈值时存储振动数据。
除此之外, 本发明还提供一种用于臂架振动监测的系统, 包括: 至少 一个上述用于臂架振动监测的车载数据单元; 数据主站, 与所述车载数据 单元通信, 用于通过无线网络接收来自所述车载数据单元的振动数据, 并 上传到远程数据中心; 远程数据中心, 与所述数据主站通信, 用于接收来 自数据主站的振动数据并对接收到的振动数据进行分析。
通过上述技术方案, 由于车载数据单元安装在混凝土泵车上, 并实时 监测臂架振动过程中的各种参数并进行记录, 这样, 如果发生振动问题, 即使技术人员不在现场, 也能记录现场第一手的振动数据, 不会因为泵车 的转移而未能及时记录数据, 而不需要技术人员赶到施工现场采集数据。 并且本发明仅在振动过大时才进行振动数据存储, 降低了存储器的存取次 数, 延长了硬件寿命。 根据本发明的优选实施方式, 车载数据单元并不保 存所有的振动数据, 而是保存与振动过大密切相关的振动数据, 这样比起 不经甄选地进行数据采集而言, 需要的存储空间大大减小, 对硬件的要求 也大大降低。 此外, 根据本发明的优选实施方式, 车载数据单元还可以将 振动数据通过无线网络发送到数据主站, 进而上传到远程数据中心以供分 本发明的其他特征和优点将在随后的具体实施方式部分予以详细说 明。 附图说明
附图是用来提供对本发明的进一步理解, 并且构成说明书的一部分, 与下面的具体实施方式一起用于解释本发明, 但并不构成对本发明的限制。 在附图中:
图 1是根据本发明提供的车载数据单元的结构框图;
图 2是根据本发明优选实施方式提供的车载数据单元的结构框图; 图 3 是根据本发明的优选实施方式提供的用于臂架振动监测的方法的 流程图;
图 4是根据本发明提供的用于臂架振动监测的系统的结构框图。 附图标记说明
1 振动检测装置 2 控制器
3 存储器 4 液压检测装置
5 无线收发器 10 车载数据单元
20 无线网络 30 数据主站
40 远程数据中心 具体实施方式
以下结合附图对本发明的具体实施方式进行详细说明。应当理解的是, 此处所描述的具体实施方式仅用于说明和解释本发明, 并不用于限制本发 明。
如图 1所示,本发明提供的用于臂架振动监测的车载数据单元 10包括: 振动检测装置 1, 用于实时检测臂架振动并输出表征臂架振动的振动信号; 控制器 2, 用于接收所述振动检测装置 1输出的振动信号以生成振动数据, 并将根据振动信号得到振动烈度与预设的振动触发阈值进行比较, 当振动 烈度超过该振动触发阈值时将振动数据发送到存储器 3 ; 存储器 3, 用于存 储接收到的所述振动数据。
其中所述振动检测装置 1 为任何能够检测臂架振动的传感器, 其能够 输出表征振动的信号, 在此称为 "振动信号"。 振动检测装置 1例如可以为 振动传感器、 位移传感器、 加速度传感器、 速度传感器中的至少一者, 其 中例如加速度传感器或速度传感器输出的虽然是加速度或速度信号, 但根 据该加速度或速度信号也能够得出振动位移, 其也能表征振动, 因此也可 以称为振动信号。
所述振动检测装置 1 可以有多个, 位于臂架的不同位置, 以检测臂架 不同位置的振动。
除了监测振动信号之外, 优选情况下, 车载数据单元 10还可以监测臂 架或混凝土泵车的其他参数, 并与振动信号一起同步记录, 用以在分析振 动过程时提供数据支持。 因此, 如图 2所示, 优选地, 该车载数据单元 10 还可以包括液压检测装置 4, 用于检测液压系统的压力并输出液压信号。所 谓液压系统可以包括主泵、 各臂节油缸, 所检测的压力也可以为主泵压力、 各臂节油缸的有杆腔和无杆腔的压力等等。 该液压检测装置 4可以为压力 传感器, 可以有多个。
根据另一种优选实施方式, 如图 2所示, 该车载数据单元 10还可以包 括臂架姿态检测装置 6, 用于实时检测臂架的当前姿态并输出姿态信号。所 谓臂架姿态检测装置 6可以为倾角传感器, 通过在各臂节上安装倾角传感 器, 可测得各臂节与水平面的倾角, 即可确定当前臂架的姿态, 姿态信号 可以为倾角信号。
此外, 车载数据单元 10还可以监控泵车内部的电气信号和操作命令信 号等等, 用以同步记录泵车的运作环境, 由于电气信号或操作命令信号本 身就是电信号, 因此可以不使用传感器等检测装置检测, 而是控制器 2直 接获取各种电信号即可, 见图 2。
所述控制器 2用于接收上述振动信号, 在上述优选情况下还接收液压 信号、 姿态信号、 电气信号和 /或操作命令信号, 以生成振动数据, 用于数 据存储。 振动数据优选以二层链表的方式来建立, 包括报头以及数据字段, 其中报头包括泵车型号、 通道号、 采集日期、 时间、 采样频率、 数据长度、 数据字段文件名等信息中的至少一者, 而至少振动信号 (优选还包括液压 信号等等) 均存储在数据字段中, 并且优选数据字段的文件名作为报头中 的一个字段, 这样可以方便检索和调用。 每个通道使用一个报头, 记录按 照通道号追加保存, 这样报头的字节数大幅减小, 数据记录的定位、 检索、 调用和复制等将非常方便迅速。
另外, 控制器 2还根据接收到的振动信号计算出振动烈度。 振动烈度 是反映振动强度的一个参数, 它可以为振动幅度的最大值、 平均值、 有效 值或均方根值等等,本领域普通技术人员根据具体采用何种振动检测装置 1 采用不同的计算方式均可以从振动信号中求得振动烈度, 因此在此不再对 计算过程详细描述。
接着, 控制器 2将计算出的振动烈度与预设的振动触发阈值相比较, 以判断是否满足存储数据的条件, 只有当振动烈度超过振动触发阈值时, 控制器 2才将振动数据发送到存储器 3进行存储。 这是因为在泵车运作过 程中, 始终会产生振动信号, 如果持续地记录振动数据, 不断存取存储器 3 会对硬件的寿命产生影响。 而如果使用本发明的这种数据存储策略, 则仅 在振动过大时进行振动数据存储, 降低了存取次数, 延长了硬件寿命。
上述振动触发阈值是预先设定的, 并且也可以随时调整, 该值的选取 与臂架的安全振动烈度有关, 一般不超过该安全振动烈度。 所谓安全振动 烈度即是臂架在这个安全振动烈度范围内振动时不会产生安全问题。
在控制器 2发送振动数据之前, 控制器 2将生成的振动数据存储在缓 存空间中, 该缓存空间可以为控制器 2的内存, 也可以是存储器 3的一部 分存储空间。 随后, 控制器 2在满足触发条件的情况下, 即振动烈度超过 振动触发阈值, 将缓存空间中的振动数据发送到存储器 3以保存。
这里所保存的振动数据可以为监控期间所生成的所有振动数据, 包括 振动烈度未超过振动触发阈值之前的振动数据以及之后生成的振动数据。 但这种方式存储量会非常大, 需要存储空间大, 并且由于数据过多也不易 管理, 一般较少采用。
另外一种方式是不全部保存, 而是只保存一部分振动数据, 这样可以 解决数据量过大的问题, 这种方式又分为两种情形。 第一种情形是: 控制 器 2将振动烈度超过振动触发阈值时当前的振动数据, 或当前的振动数据 以及之后生成的振动数据, 或当前的振动数据以及之后一段时间生成的振 动数据, 发送到存储器 3。这种方式降低了存储量, 一方面相对全部保存而 言节省了存储空间, 另一方面所存储的数据均是对于后期分析有价值的数 据, 便于管理, 记录效率也高。 但是这种方式并没有保存振动烈度过大之 前的振动数据, 缺少这部分数据不利于后期分析产生过大的振动的原因。 因此, 优选是采用下面第二种情形, 控制器 2将振动烈度超过振动触发阈 值的时刻之前一段时间到之后一段时间内生成的振动数据发送到存储器 3。 这种方式既节省了存储空间, 也保存了整个振动过大过程的振动数据, 便 于统计分析。
上述第二种情形采用的是缓存空间先入先出的数据存储方式, 也就是 说, 最新添加到缓存空间的是当前时刻生成的振动数据, 并且缓存空间只 保存一段连续的数据, 之前的数据可以舍弃。 这样, 优选地, 控制器 2用 于将从 trT至 t2+T时刻之间生成的振动数据发送到存储器 3, 其中 ^为振 动烈度超过振动触发阈值的时刻, t2是 ^之后振动烈度再次小于振动触发阈 值的时刻, T为冗余时间段, T的取值范围为 0≤T≤Tmax, Tmax为缓存空间所 能存储的振动数据的最大连续时间段。 T的取值可以为 0, 此时存储的范围 为 ^至 之间, 记录的恰好是振动烈度超振动触发阈值的整个过程, 但为 了分析前后振动过程,所以优选还是 T大于 0, 以将整个发展过程都包含进 来。 缓存空间所能存储的振动数据的最大连续时间段 Tmax依赖于缓存空间 的大小、 振动数据的生成频率、 每次生成的振动数据的大小, 例如, 可以 根据下述公式计算 Tmax:
Tmax=缓存空间的大小 / (振动数据的生成频率 *平均每次生成的振动数 据的大小)。
上述优选实施方式的具体实现过程如下所述: 在出现振动烈度超过振 动触发阈值时 时刻, 即当前时刻), 向前追溯到 trT的时刻, 将缓存空 间中 trT至 这段时间内生成的振动数据转存到存储器 3。 如果 ^<1\ 则 只追溯到 0时刻, 即起始时刻。 此外, 由于在 trT之前的这段时间内, 也 没有出现振动烈度超过振动触发阈值的情况, 此时可以将缓存空间中 trT 时刻之前的振动数据删除。 此时振动还继续进行, 振动数据被继续转存, 直到在 t2时刻, 振动烈度再次小于振动触发阈值时, 这意味着振动回归到 正常状态, 此时只需要在此基础上再保留 τ时间段内的振动数据即可。 当 然, 如果在 至 t2+T时间段之内再次发生振动烈度超过振动触发阈值的情 况 (该时刻可以被认定为新的 ), 由于 至 +丁时间段肯定处 至 新的 t2'+T的区间内,所以 至 +1这部分数据也被转存, 同时也满足上述 技术方案。
所述存储器 3为一般的数据存储装置, 可以集成在控制器 2中, 也可 以为外部存储器。
进一步, 为了便于振动数据向外输出, 如图 2所示, 根据本发明的优 选技术方案, 所述车载数据单元 10还包括无线收发器 5, 用于通过无线网 络发送存储器 3所存储的振动数据。 该无线收发器 5可以为使用各种无线 通信协议的数字收发器, 例如射频、 GSM、 GPRS, CDMA无线收发器等。
本发明还提供一种具有臂架的工程机械, 上述车载数据单元 10安装在 该工程机械上, 用于实时监测该工程机械的臂架的振动情况, 并记录数据。 这样, 如果发生振动问题, 即使技术人员不在现场, 也能记录现场第一手 的振动数据, 不会因为泵车的转移而未能及时记录数据。 虽然本发明以混 凝土泵车作为示例予以解释说明, 但本领域技术人员均可以理解, 凡是具 有臂架的工程机械均可以使用本发明提供的车载数据单元以及下面讲到的 系统。
根据本发明的另一方面, 还提供一种用于臂架振动监测的方法, 该方 法包括以下步骤:
实时检测臂架振动并得到表征臂架振动的振动信号;
根据所述振动信号生成振动数据, 并将根据振动信号得到的振动烈度 与预设的振动触发阈值进行比较; 以及
当振动烈度超过该振动触发阈值时存储振动数据。
3为本发明提供的优选实施方式, 下面结合图 3介绍本发明所提供 的方法。 其中虚线框表示的是优选步骤, 并非必要步骤。
如图 3所示, 在检测臂架振动并得到振动信号的同时, 如前所述, 还 可以实时检测液压系统的压力并得到液压信号, 也可以实时检测臂架的姿 态并得到姿态信号, 也可以获取电气信号和 /或操作命令信号。 这样, 所述 振动数据是可以根据液压信号、 姿态信号、 电气信号、 操作命令信号中的 至少一者和振动信号生成的。 同样如前所述, 振动数据优选以上面提到的 二层链表的方式来建立, 包括报头以及数据字段, 其中报头包括泵车型号、 通道号、 采集日期、 时间、 采样频率、 数据长度、 数据字段文件名等信息, 而振动信号、 液压信号等等均存储在数据字段中, 并且数据字段的文件名 作为报头中的一个字段。
另外, 如何根据接收到的振动信号得到振动烈度、 如何比较振动烈度 与预设的振动触发阈值、 以及如何存储振动数据均在前面介绍车载数据单 元 10时进行了说明。 特别地, 优选存储振动烈度超过振动触发阈值的时刻之前一段时间到 之后一段时间内生成的振动数据。 更优选地, 存储从 trT至 t2+T时刻之间 生成的振动数据。 其中各参数意义与前述相同, 不再赘述。
进一步, 为了便于振动数据向外输出, 该方法还包括: 通过无线网络 发送所存储的振动数据 (未图示)。
根据本发明的又一方面, 如图 4所示, 本发明还提供一种用于臂架振 动监测的系统, 其中, 该系统包括: 至少一个本发明优选实施方式提供的 用于臂架振动监测的车载数据单元 10 (其中包括无线收发器); 数据主站 30, 与所述车载数据单元 10通信, 用于通过无线网络 20接收来自所述车 载数据单元 10的振动数据, 并上传到远程数据中心 40; 远程数据中心 40, 与所述数据主站 30通信, 用于接收来自数据主站 30的振动数据并对接收 到的振动数据进行分析。
其中数据主站 30安装在待监测泵车所属的技术服务站, 一个技术服务 站可以监测一定地理范围内 (无线传输所能覆盖的范围) 的多台泵车。 数 据主站 30主要起到振动数据的汇总和中转的作用, 因此数据主站 30主要 包括服务器, 具有无线接收、 数据汇总存储、 以及传输数据的功能, 常规 的服务器均可以实现。 数据主站 30可以采用周期性上传、 应远程数据中心 40的请求上传、应车载数据单元 10的请求上传等各种上传方式。数据主站 30也可以有多个, 分散在不同区域。
远程数据中心 40设置在制造企业的技术研发部门, 因为泵车的施工地 点与制造企业之间可能距离较远, 不便于直接通过无线网络来传递数据, 所以振动数据先通过无线传输的方式被发送到数据主站 30中, 然后数据主 站 30再通过有线通信网络将数据转发到远程数据中心 40。 远程数据中心 40包括远程振动数据库以及 WEB服务器,通过 WEB服务器将来自数据主 站的振动数据输入到远程振动数据库中, 以供分析。 通过这种通信模式, 可以在远程实现对泵车的振动性能的追踪监测, 技术人员不必亲临现场就 可以掌握到现场的数据, 对于售后服务维护、 臂架振动性能的监控、 产品 的改进都有益处。
以上结合附图详细描述了本发明的优选实施方式, 但是, 本发明并不 限于上述实施方式中的具体细节, 在本发明的技术构思范围内, 可以对本 发明的技术方案进行多种简单变型, 这些简单变型均属于本发明的保护范 围。
另外需要说明的是, 在上述具体实施方式中所描述的各个具体技术特 征, 在不矛盾的情况下, 可以通过任何合适的方式进行组合, 为了避免不 必要的重复, 本发明对各种可能的组合方式不再另行说明。
此外, 本发明的各种不同的实施方式之间也可以进行任意组合, 只要 其不违背本发明的思想, 其同样应当视为本发明所公开的内容。

Claims

权利要求
1.一种用于臂架振动监测的车载数据单元,其中,该车载数据单元(10) 包括:
振动检测装置(1 ), 用于实时检测臂架振动并输出表征臂架振动的振动 信号;
控制器 (2), 用于接收所述振动检测装置 (1 ) 输出的振动信号以生成 振动数据, 并将根据振动信号得到振动烈度与预设的振动触发阈值进行比 较, 当振动烈度超过该振动触发阈值时将振动数据发送到存储器 (3 );
存储器 (3 ), 用于存储接收到的所述振动数据。
2. 根据权利要求 1所述的车载数据单元, 其中, 所述振动检测装置(1 ) 为振动传感器、 位移传感器、 加速度传感器、 速度传感器中的至少一者。
3. 根据权利要求 1所述的车载数据单元, 其中, 该车载数据单元还包 括液压检测装置(4)和 /或臂架姿态检测装置(6), 液压检测装置(4)用于 实时检测液压系统的压力并输出液压信号, 臂架姿态检测装置 (6) 用于实 时检测臂架的当前姿态并输出姿态信号;
所述控制器 (2 ) 还用于接收电气信号、 操作命令信号、 所述液压信号 以及姿态信号中的至少一者, 并且根据所述液压信号、 姿态信号、 电气信号 和操作命令信号中的至少一者以及所述振动信号来生成所述振动数据。
4. 根据权利要求 1所述的车载数据单元, 其中, 控制器 (2)所生成的 振动数据包括报头以及数据字段, 其中报头包括泵车型号、 通道号、 采集日 期、 时间、 采样频率、 数据长度、 数据字段文件名中至少一者, 数据字段至 少包括振动信号。
5. 根据权利要求 1所述的车载数据单元, 其中, 所述控制器 (2 )用于 将从振动烈度超过该振动触发阈值的时刻之前一段时间到之后一段时间内 生成的振动数据发送到存储器 (3 )。
6. 根据权利要求 5所述的车载数据单元, 其中, 所述控制器 (2 )用于 将从 trT至 t2+T时刻之间生成的振动数据发送到存储器 (3 ), 其中 ^为振 动烈度超过振动触发阈值的时刻, 是 ^之后振动烈度再次小于振动触发阈 值的时刻, T为冗余时间段, T的取值范围为 0≤T≤Tmax, Tmax为缓存空间所 能存储的振动数据的最大连续时间段。
7. 根据权利要求 6所述的车载数据单元, 其中, 缓存空间所能存储的 振动数据的最大连续时间段 Tmax=缓存空间的大小 / (振动数据的生成频率 * 平均每次生成的振动数据的大小)。
8. 根据权利要求 1-7 中任一项所述的车载数据单元, 其中, 所述车载 数据单元 (10) 还包括无线收发器 (5 ), 用于通过无线网络发送存储器 (3 ) 所存储的振动数据。
9. 一种具有臂架的工程机械, 包括根据权利要求 1-8 中任一项所述用 于臂架振动监测的车载数据单元 (10)。
10. 一种用于臂架振动监测的方法, 其中, 该方法包括以下步骤: 实时检测臂架振动并得到表征臂架振动的振动信号;
根据所述振动信号生成振动数据,并将根据振动信号得到的振动烈度与 预设的振动触发阈值进行比较; 以及
当振动烈度超过该振动触发阈值时存储振动数据。
11. 根据权利要求 10所述的方法, 其中, 该方法还包括以下步骤中的 至少一者:
实时检测液压系统的压力并得到液压信号;
实时检测臂架的姿态并得到姿态信号;
获取电气信号; 和
获取操作命令信号;
并且,根据所述振动信号生成振动数据的步骤中所述振动数据是根据液 压信号、 姿态信号、 电气信号、 操作命令信号中的至少一者和振动信号生成 的。
12. 根据权利要求 10所述的方法, 其中, 所生成的振动数据包括报头 以及数据字段, 其中报头包括泵车型号、 通道号、 采集日期、 时间、 采样频 率、 数据长度、 数据字段文件名中至少一者, 数据字段至少包括振动信号。
13. 根据权利要求 10所述的方法, 其中, 所存储的振动数据为振动烈 度超过振动触发阈值的时刻之前一段时间到之后一段时间内生成的振动数 据。
14. 根据权利要求 13所述的方法, 其中, 所存储的振动数据为从 trT 至 t2+T时刻之间生成的振动数据,其中 ^为振动烈度超过振动触发阈值的时 刻, 是^之后振动烈度再次小于振动触发阈值的时刻, T为冗余时间段, T 的取值范围为 0≤T≤Tmax, Tmax为缓存空间所能存储的振动数据的最大连续时 间段。
15. 根据权利要求 14所述的方法, 其中, 缓存空间所能存储的振动数 据的最大连续时间段 Tmax=缓存空间的大小 / (振动数据的生成频率 *平均每 次生成的振动数据的大小)。
16. 一种用于臂架振动监测的系统, 其中, 该系统包括:
至少一个根据权利要求 8 所述的用于臂架振动监测的车载数据单元 ( 10);
数据主站 (30), 与所述车载数据单元 (10) 通信, 用于通过无线网络
(20) 接收来自所述车载数据单元 (10) 的振动数据, 并上传到远程数据中 心 (40);
远程数据中心 (40), 与所述数据主站 (30) 通信, 用于接收来自数据 主站 (30) 的振动数据并对接收到的振动数据进行分析。
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