Real-time monitoring device and method for comprehensive wear condition of winch hoist gear

Abstract

A real-time monitoring device and method for the comprehensive wear condition of the gears of a winch-type gate hoist, the device comprises a motor, the motor is connected to the large gear at the end of the drum shaft through a reducer and a small gear, a motor angular velocity rotation encoding sensor is arranged at the end of the motor shaft, a motor vibration sensor is also arranged on the motor, a drum shaft end vibration sensor is arranged at the end of the drum shaft, a drum shaft end follower cable system component is arranged at the lower part of the drum shaft end, and the motor, the motor angular velocity rotation encoding sensor, the motor vibration sensor, and the drum shaft end vibration sensor are all connected to a controller. The present invention can obtain the comprehensive gear wear condition of the winch-type gate hoist in real time in an online manner, can realize early warning of the operating safety of the gate hoist and guide the operation and maintenance personnel to perform predictive maintenance.

Description

Technical Field

[0001] The present invention relates to the technical field of gate hoists in water conservancy and hydropower projects, and specifically to a real-time monitoring device for a winch-type gate hoist, and also to a real-time monitoring method for the gate hoist. Background Art

[0002] The winch gate hoist is an important permanent equipment in water conservancy and hydropower projects, and its own operating safety directly affects the safety of reservoir dams. Since the winch gate hoist is a heavy-load operating equipment, the wear of its gear transmission system is relatively serious, especially in the western region and the Hetao Plain area with strong winds and sand.

[0003] Currently, there is no real-time online method to obtain the comprehensive gear wear condition of the winch gate hoist in real time, let alone to achieve early warning of the operating safety status of the winch gate hoist and guide the operation and maintenance personnel to perform predictive maintenance. Summary of the invention

[0004] In order to obtain the comprehensive gear wear condition of the winch-type gate hoist in real time online, and to achieve early warning of the operating safety status of the winch-type gate hoist and guide the operation and maintenance personnel to perform predictive maintenance.

[0005] The purpose of the present invention is to provide a real-time monitoring device and method for the wear condition of the gears of a winch-type gate hoist, which can monitor the gear wear condition in real time, realize early warning of the operating safety condition of the winch-type gate hoist and guide operation and maintenance personnel to perform predictive maintenance.

[0006] The purpose of the present invention is achieved through the following technical solutions:

[0007] A real-time monitoring device for the comprehensive wear condition of the gears of a winch-type gate hoist comprises a motor, which is connected to a large gear at the end of a drum shaft through a reducer and a small gear, a motor angular velocity rotation encoding sensor is arranged at the end of the motor shaft, a motor vibration sensor is also arranged on the motor, a drum shaft end vibration sensor is arranged at the end of the drum shaft, a drum shaft end follow-up cable system component is arranged at the lower part of the drum shaft end, and the motor, the motor angular velocity rotation encoding sensor, the motor vibration sensor and the drum shaft end vibration sensor are all connected to a controller.

[0008] The above-mentioned real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist, the motor angular velocity rotary encoding sensor is composed of a signal acquisition unit and a pancake-shaped permanent magnet, the signal acquisition unit is a PCB circuit board, an angular velocity rotary encoder chip is welded at the center of the PCB circuit board, the pancake-shaped permanent magnet is adsorbed to the end of the motor rotating shaft, the PCB circuit board is installed along the axis of the motor, the angular velocity rotary encoder chip corresponds to the pancake-shaped permanent magnet iron, the angular velocity rotary encoder chip is connected to the PCB circuit board through a wire, and the PCB circuit board is connected to the controller.

[0009] In the above-mentioned real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist, the angular velocity rotary encoder chip is 1.5mm-3mm away from the pancake-shaped permanent magnet.

[0010] The above-mentioned real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist, the motor vibration sensor is a three-axis acceleration sensor installed on the upper heat dissipation fins of the motor, and the three-axis acceleration sensor is connected to the controller through a wire.

[0011] The above-mentioned real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist, the follow-up cable system component at the end of the drum shaft includes a rotating shaft installed at the end of the drum shaft, a wire is fixed on the rotating shaft, one end of the wire is connected to the vibration sensor at the end of the drum shaft, and the other end of the wire extends to the bottom of the rotating shaft, and a shell is arranged below the rotating shaft, and the shell is fixed to the frame at the end of the drum shaft through a fixing seat, two fixed pulleys are fixed on the upper part of the shell, and two gravity pulleys are arranged at the lower part of the shell, and the wire extending below the rotating shaft is connected to the controller after bypassing the first gravity pulley, the first fixed pulley, the second gravity pulley and the second fixed pulley in sequence.

[0012] A real-time monitoring method for the comprehensive wear condition of a winch hoist gear comprises the following steps:

[0013] a. Install a motor angular velocity rotary encoding sensor at the end of the motor, and install a motor vibration sensor on the motor fin; the motor angular velocity rotary encoding sensor and the motor vibration sensor are connected to the controller;

[0014] b. A reel shaft end vibration sensor is provided at the end of the reel shaft, and the reel shaft end vibration sensor is connected to the controller;

[0015] c. Start the motor. The motor vibration sensor reads the change in the motor's angular momentum. After calculation, the trigger signal is transmitted to the controller, which is recorded as t0. The controller reads the initial angle value of the motor's angular velocity rotation encoder sensor at time t0, which is recorded as N0.

[0016] When the power is transmitted to the large gear of the reel, the vibration sensor at the end of the reel shaft reads the angular momentum value generated by the rotation of the reel at the moment. After calculation, the trigger signal is transmitted to the controller, which is recorded as t1. The controller reads the angle value of the motor angular velocity rotation encoder sensor at time t1, which is recorded as N1.

[0017] d. From t0 when the motor starts to t1 when the drum starts running, the angle N = N1-N0 that the motor rotates during the time period t = t1-t0 can reflect the idle state of the gear set of the gate hoist; when the gears in the gear set are worn, the idle state will change, and the value of N will gradually increase with the wear of the gears in the gear set. When the increase in the N value is observed to exceed the threshold value N' set by the controller, the equipment should be maintained.

[0018] By adopting the above technical solution, the beneficial effects of the present invention are:

[0019] The present invention arranges a motor angular velocity rotation encoding sensor and a motor vibration sensor on the motor, as well as a drum shaft end vibration sensor at the end of the drum shaft, to respectively collect the angle value and angular momentum change value at the moment of motor startup, and the angular momentum change value generated at the moment of the drum shaft end starting, and then performs a subtraction calculation, and compares it with the threshold value set in the controller. If it exceeds the set threshold value, it means that the gear wear is relatively serious, and an early warning is required and the equipment needs to be maintained.

[0020] The present invention can obtain the comprehensive gear wear condition of the winch-type gate hoist in real time in an online manner, can provide early warning of the operating safety condition of the gate hoist and guide operation and maintenance personnel to perform predictive maintenance.

[0021] The present invention is applicable to the case where there is a return difference in the gear transmission when the gear rotates forward and reverse alternately. The device monitors the change of the return difference to judge the wear condition of the gear set. That is, after the hoist is opened and closed alternately, real-time monitoring is performed. If it is always in the open state or always in the closed state, no real-time monitoring is performed. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of the present invention.

[0023] Figure 2 It is a schematic diagram of the structure of the motor of the present invention.

[0024] Figure 3 It is a schematic diagram of the structure of the motor angular velocity rotation encoding sensor of the present invention.

[0025] Figure 4 It is a schematic diagram of the structure of the reel shaft end of the present invention.

[0026] Figure 5It is a schematic structural diagram of the follower cable system components at the end of the drum shaft of the present invention. DETAILED DESCRIPTION

[0027] The following is combined with Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 The structure and working process of the present invention are specifically described in detail.

[0028] Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 Figure numbers:

[0029] 1 is the motor angular velocity rotary encoder sensor, 2 is the motor vibration sensor, 3 is the end of the drum shaft, 4 is the vibration sensor of the drum shaft end, 5 is the follow-up cable system component of the drum shaft end, 6 is the controller, 7 is the pancake-shaped permanent magnet, 8 is the end of the motor rotating shaft, 9 is the motor housing, 10 is the angular velocity rotary encoder chip, 11 is the PCB circuit board, 12 is the housing, 13 is the fixing seat, 14 is the fixed pulley, 15 is the gravity pulley, 16 is the rotating shaft, and 17 is the wire 17.

[0030] A real-time monitoring device for the comprehensive wear condition of the gear of a winch-type gate hoist, such as Figures 1 to 5 As shown, it includes an electric motor, which is connected to a large gear at the end of a drum shaft 3 through a reducer and a small gear. A motor angular velocity rotation encoding sensor 1 is arranged at the end of the motor shaft, a motor vibration sensor 2 is also arranged on the motor, a drum shaft end vibration sensor 4 is arranged at the end of the drum shaft, and a drum shaft end follow-up cable system component 5 is arranged at the lower part of the drum shaft end. The motor, the motor angular velocity rotation encoding sensor, the motor vibration sensor, and the drum shaft end vibration sensor are all connected to a controller 6.

[0031] The real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist, further scheme, such as Figure 3 As shown, the motor angular velocity rotary encoder sensor is composed of a signal acquisition unit and a pancake-shaped permanent magnet 7. The signal acquisition unit is a PCB circuit board 11. An angular velocity rotary encoder chip 10 is welded at the center of the PCB circuit board. The pancake-shaped permanent magnet is adsorbed to the end 8 of the motor rotating shaft of the motor housing 9. The PCB circuit board is installed along the axis of the motor. The angular velocity rotary encoder chip corresponds to the pancake-shaped permanent magnet. The angular velocity rotary encoder chip is connected to the PCB circuit board through a wire, and the PCB circuit board is connected to the controller 6.

[0032] A further solution of the real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist is that the angular velocity rotary encoder chip is 1.5mm-3mm away from the pancake-shaped permanent magnet.

[0033] A further solution of the real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist is that the motor vibration sensor is a three-axis acceleration sensor installed on the upper heat dissipation fins of the motor, and the three-axis acceleration sensor is connected to the controller through a wire.

[0034] The real-time monitoring device for the comprehensive wear condition of the gear of the winch-type gate hoist, further scheme, such as Figure 4 and Figure 5 As shown, the follower cable system component 5 at the end of the drum shaft includes a rotating shaft 16 installed at the end of the drum shaft, a wire 17 is wound on the rotating shaft, one end of the wire is connected to the vibration sensor 4 at the end of the drum shaft, and the other end of the wire is wound through the circumscribed circle of the rotating shaft and extends to the bottom of the rotating shaft, a shell 12 is arranged under the rotating shaft, the shell is fixed to the frame at the end of the drum shaft through a fixing seat 13, two fixed pulleys 14 are fixed on the upper part of the shell, and two gravity pulleys 15 are arranged at the lower part of the shell, and the wire extending to the bottom of the rotating shaft is connected to the controller after bypassing the first gravity pulley, the first fixed pulley, the second gravity pulley and the second fixed pulley in sequence.

[0035] A real-time monitoring method for the comprehensive wear condition of a winch hoist gear comprises the following steps:

[0036] a. Install a motor angular velocity rotary encoding sensor at the end of the motor, and install a motor vibration sensor on the motor fin; the motor angular velocity rotary encoding sensor and the motor vibration sensor are connected to the controller;

[0037] b. A reel shaft end vibration sensor is provided at the end of the reel shaft, and the reel shaft end vibration sensor is connected to the controller;

[0038] c. Start the motor. The motor vibration sensor reads the change in the motor's angular momentum. After calculation, the trigger signal is transmitted to the controller, which is recorded as t0. The controller reads the initial angle value of the motor's angular velocity rotation encoder sensor at time t0, which is recorded as N0.

[0039] When the power is transmitted to the large gear of the reel, the vibration sensor at the end of the reel shaft reads the angular momentum value generated by the rotation of the reel at the moment. After calculation, the trigger signal is transmitted to the controller, which is recorded as t1. The controller reads the angle value of the motor angular velocity rotation encoder sensor at time t1, which is recorded as N1.

[0040] d. From t0 when the motor starts to t1 when the drum starts running, the angle N = N1-N0 that the motor rotates during the time period t = t1-t0 can reflect the idle state of the gear set of the gate hoist; when the gears in the gear set are worn, the idle state will change, and the value of N will gradually increase with the wear of the gears in the gear set. When the increase in the N value is observed to exceed the threshold value N' set by the controller, the equipment should be maintained.

[0041] During operation, the gate opening and closing machine of the present invention will perform operations to open and close the gate, which is the forward and reverse rotation of the gear for the gear transmission. When the gear rotates forward and reverse alternately, there is a return difference in the gear transmission. The device monitors the change of the return difference to determine the wear condition of the gear set.

[0042] When the gate hoist changes from forward operation to reverse operation (or reverse operation to forward operation), the power transmission process is: motor-coupling-reducer-pinion gear-large gear. In the process of power transmission, the motor is the initial output end of power, and the large gear is the end of the power output of the gear set.

[0043] At the moment when the motor starts to rotate, according to the law of conservation of angular momentum, the rotation of the motor output shaft will inevitably cause the motor housing to generate corresponding angular momentum in the opposite direction of rotation. The change in angular momentum will be captured by the acceleration sensor installed on the heat dissipation fins of the motor housing. When the control unit obtains the angular momentum change state of the motor, this time is recorded as t0. The control unit reads the angle value on the motor angular velocity rotation encoding sensor through the control loop at time t0, which is recorded as N0. After reading the motor angle value, the control unit starts to monitor the vibration sensor at the end of the reel shaft. When the power is transmitted to the reel gear, the vibration sensor at the end of the reel shaft can capture the acceleration value generated by the moment the reel rotates, which is recorded as t1. The control unit reads the angle value on the motor angular velocity rotation encoding sensor again through the control loop at time t1, which is recorded as N1.

[0044] From the time when the motor starts t0 to the time when the drum starts running t1, the angle N = N1-N0 that the motor rotates during the time period t = t1-t0 can reflect the idle state of the hoist gear set. When the gears in the gear set are worn, the idle state will change, and the value of N will gradually increase with the wear of the gears in the gear set. When the increase in the N value exceeds the set threshold, the equipment can be maintained.

[0045] It should be noted that:

[0046] 1. If the gate hoist stops after forward operation and restarts in forward operation, or stops after reverse operation and restarts in reverse operation, the N value monitored by the system is close to 0. Only when the gate hoist changes from forward operation to reverse operation (or reverse operation to forward operation), the N value monitored by the system is a valid monitoring value. That is, the real-time monitoring is effective only after the gate hoist is opened and closed alternately. If it is always in the open state or always in the closed state, the real-time monitoring is invalid. These can be set in the controller.

[0047] 2. If the reel starts running after the motor rotates more than 360 degrees, the rotary encoder has started the second axis angle test. The calculation of N = N1-N0 will miss the rotation value of the entire cycle. At this time, it can be corrected by changing t = t1-t0.

[0048] The above is only a preferred embodiment of the present invention. It should be pointed out that for those skilled in the art, several changes and improvements can be made without departing from the overall concept of the present invention. These should also be regarded as the scope of protection of the present invention. These will not affect the effect of the implementation of the present invention and the practicality of the patent.

Claims

1. A real-time monitoring device for the comprehensive wear condition of winch hoist gears, comprising a motor, the motor is connected to the large gear at the end of the drum shaft through a reducer and a small gear, and a motor angular velocity rotary encoder sensor is arranged at the end of the motor shaft, characterized in that: A motor vibration sensor is also arranged on the motor, a reel shaft end vibration sensor is arranged at the end of the reel shaft, a reel shaft end follower cable system component is arranged at the lower part of the reel shaft end, and the motor, the motor angular velocity rotation encoding sensor, the motor vibration sensor, and the reel shaft end vibration sensor are all connected to the controller; The real-time monitoring method for the comprehensive wear condition of the winch hoist gear is as follows: The gate hoist is first opened and closed alternately, and then real-time monitoring is performed. The specific monitoring steps are as follows: a. Install a motor angular velocity rotary encoding sensor at the end of the motor, and install a motor vibration sensor on the motor fin; the motor angular velocity rotary encoding sensor and the motor vibration sensor are connected to the controller; b. A reel shaft end vibration sensor is provided at the end of the reel shaft, and the reel shaft end vibration sensor is connected to the controller; c. Start the motor. The motor vibration sensor reads the change in the motor's angular momentum. After calculation, the trigger signal is transmitted to the controller, which is recorded as t0. The controller reads the initial angle value of the motor's angular velocity rotation encoder sensor at time t0, which is recorded as N0. When the power is transmitted to the large gear of the reel, the vibration sensor at the end of the reel shaft reads the angular momentum value generated by the rotation of the reel at the moment. After calculation, the trigger signal is transmitted to the controller, which is recorded as t1. The controller reads the angle value of the motor angular velocity rotation encoder sensor at time t1, which is recorded as N1. d. From t0 when the motor starts to t1 when the drum starts running, the angle N = N1 -N0 that the motor rotates during the time period t = t1 -t0 can reflect the idle state of the gear set of the gate hoist; when the gears in the gear set are worn, the idle state will change, and the value of N will gradually increase with the wear of the gears in the gear set. When the increase in the N value is observed to exceed the threshold value N' set by the controller, the equipment needs to be maintained accordingly.

2. The real-time monitoring device for comprehensive wear condition of winch hoist gear according to claim 1 is characterized in that: The motor angular velocity rotary encoder sensor is composed of a signal acquisition unit and a pancake-shaped permanent magnet. The signal acquisition unit is a PCB circuit board. An angular velocity rotary encoder chip is welded at the center of the PCB circuit board. The pancake-shaped permanent magnet is adsorbed to the end of the motor rotating shaft. The PCB circuit board is installed along the axis of the motor. The angular velocity rotary encoder chip corresponds to the pancake-shaped permanent magnet. The angular velocity rotary encoder chip is connected to the PCB circuit board through a wire, and the PCB circuit board is connected to a controller.

3. The real-time monitoring device for comprehensive wear condition of winch hoist gear according to claim 2 is characterized in that: The angular velocity rotary encoder chip is 1.5 mm to 3 mm away from the pancake-shaped permanent magnet.

4. The real-time monitoring device for comprehensive wear condition of winch hoist gear according to claim 1 is characterized in that: The motor vibration sensor is a three-axis acceleration sensor installed on the upper heat dissipation fins of the motor, and the three-axis acceleration sensor is connected to the controller through a wire.

5. The real-time monitoring device for comprehensive wear condition of winch hoist gear according to claim 1 is characterized in that: The follow-up cable system component at the end of the drum shaft includes a rotating shaft installed at the end of the drum shaft, a wire is wound on the rotating shaft, one end of the wire is connected to the vibration sensor at the end of the drum shaft, and the other end of the wire is wound through the circumscribed circle of the rotating shaft and extends to the bottom of the rotating shaft, a shell is arranged under the rotating shaft, the shell is fixed to the frame at the end of the drum shaft through a fixing seat, two fixed pulleys are fixed on the upper part of the shell, and two gravity pulleys are arranged at the lower part of the shell, and the wire extending under the rotating shaft is connected to the controller after bypassing the first gravity pulley, the first fixed pulley, the second gravity pulley and the second fixed pulley in sequence.

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