A bridge inspection vehicle performance evaluation and early warning system and method

Abstract

This invention provides a bridge inspection vehicle performance evaluation and early warning system and method, including a storage module, a power module, a master switch, a human-machine interface, indicator lights, an angle sensor, a motor driver, and a wireless communication module, all electrically connected to a processing module. The angle sensor collects the angular deviation of the synchronous walking mechanisms on the left and right sides of the bridge inspection vehicle; the processing module issues early warnings or fault alarms based on the angular deviations; the indicator lights indicate the early warnings or fault alarms; the power module supplies power to all modules of the bridge inspection vehicle performance evaluation and early warning system; the power module is also electrically connected to a circuit breaker, which is electrically connected to a switching power supply; the motor driver is also electrically connected to a drive motor to control the motor's speed, thereby achieving speed control. This system enables performance evaluation and early warning of the inspection vehicle, reducing hidden safety risks during its use.

Description

Technical Field

[0001] The present invention relates to the field of bridge equipment monitoring and control, and in particular to a bridge inspection vehicle performance evaluation and early warning system and method. Background Art

[0002] The bridge inspection vehicle is a movable inspection platform installed on a traffic bridge for inspection operations; through the overall movement of the inspection vehicle or the movement of the internal mechanism, the inspection operators on the inspection vehicle can reach all parts of the bridge that need to be inspected. The inspection vehicle mainly solves the accessibility and safety of bridge inspection operations, and can provide a safe and reliable working platform for daily inspection, testing, maintenance and upkeep of bridges.

[0003] In the control of traditional linear synchronous movement, variable frequency speed control combined with analog control is mainly used to achieve the synchronous movement of the trolley in an open-loop or semi-closed-loop manner. The detection uses travel switches and proximity switches. Due to the influence of many factors such as the size error of mechanical parts, assembly error, and the parallelism of the left and right trolley tracks, friction coefficient, and resistance at the joints, the inspection vehicle will form a large cumulative error during the movement. The relative displacement of the left and right drive trolleys becomes larger, which is easy to cause the trolley to get stuck or derailed, posing a great safety hazard. As the service time of the bridge inspection vehicle becomes longer and longer, the wear of the parts related to the walking structure on the left and right sides is gradually serious, affecting the synchronization performance of the inspection vehicle. Therefore, how to accurately and effectively evaluate the performance of the inspection vehicle and give early warnings to reduce the hidden safety risks in the use of the inspection vehicle is an important issue currently faced. Summary of the invention

[0004] The present invention provides a bridge inspection vehicle performance evaluation and early warning system and method, which mainly solves the technical problem of how to accurately and effectively perform performance evaluation and early warning on the inspection vehicle to reduce the hidden safety risks existing during the use of the inspection vehicle.

[0005] In order to solve the above technical problems, the present invention provides a bridge inspection vehicle performance evaluation and early warning system, including a storage module, a power module, a main switch, a human-machine interface, an indicator light, an angle sensor, a motor driver and a wireless communication module, which are electrically connected to the processing module respectively; the angle sensor is used to collect the angle deviation of the synchronous walking mechanism on the left and right sides of the bridge inspection vehicle, and the processing module is used to make an early warning or a fault alarm according to the angle deviation; the storage module is used to store the angle deviation data collected by the angle sensor and the early warning or fault alarm result data of the processing module; the indicator light is used to indicate the early warning or fault alarm respectively; the power module is used to supply power to each module of the bridge inspection vehicle performance evaluation and early warning system; the power module is also electrically connected to the circuit breaker, and the circuit breaker is electrically connected to the switching power supply; the motor driver is also electrically connected to the drive motor to control the rotation speed of the drive motor, thereby realizing speed control.

[0006] Optionally, it also includes an offset limit switch, which is electrically connected to the processing module and is used to trigger the offset limit switch when the deflection angle of the left and right synchronous walking mechanisms of the bridge inspection vehicle exceeds the limit angle, so as to stop the left and right synchronous walking mechanisms from continuing to operate; at this time, the processing module is also used to generate fault alarm result data; the storage module is also used to store the fault alarm result data.

[0007] Optionally, the processing module includes one of a CPU central processing unit, a single chip microcomputer, a microprocessor, and a PLC control module.

[0008] Optionally, the motor driver includes a left motor driver and a right motor driver, the drive motor includes a left drive motor and a right drive motor, the left motor driver is electrically connected to the left drive motor, and is used to control the rotation speed of the left drive motor to achieve speed control of the left side synchronous walking mechanism of the bridge inspection vehicle; the right motor driver is electrically connected to the right drive motor, and is used to control the rotation speed of the right drive motor to achieve speed control of the right side synchronous walking mechanism of the bridge inspection vehicle.

[0009] Optionally, the wireless communication module includes a WiFi / 4G / 5G mobile communication module, which is used to send the early warning or fault alarm result data to a remote monitoring platform to achieve remote monitoring.

[0010] The present invention also provides a method of a bridge inspection vehicle performance evaluation and early warning system as described in any one of the above items, comprising:

[0011] Angle sensors are used to monitor and collect the angle deviations of the synchronous walking mechanisms on the left and right sides of the bridge inspection vehicle in real time, and the angle fluctuation rate is calculated. The angle fluctuation rate is compared with the warning threshold and the fault threshold. When the angle fluctuation rate is lower than the warning threshold, it indicates that the bridge inspection vehicle is in normal operation; when the angle fluctuation rate is greater than or equal to the warning threshold and less than the fault threshold, a warning result is generated, and the indicator light is controlled to indicate a warning in the first state; when the angle fluctuation rate is greater than or equal to the fault threshold, a fault result is generated, and the indicator light is instructed to indicate a fault in the second state; the fault threshold is higher than the warning threshold; and the warning or fault alarm result data is stored in a memory;

[0012] According to the set time period, the warning result data and the fault result data generated within the set time period are regularly obtained from the memory;

[0013] Counting the number of warning results and the number of fault results within the set time period;

[0014] Calculating a performance score of the bridge inspection vehicle according to the number of warning results and the number of failure results within the set time period;

[0015] The performance score is sent to a human-machine interface in real time for display, and is remotely sent to a remote monitoring platform to achieve remote monitoring.

[0016] Optionally, the first state is a yellow indicator light, and the second state is a red indicator light.

[0017] Optionally, the set time period includes one of the most recent day, the most recent three days, the most recent week, and the most recent month.

[0018] Optionally, the calculating the performance score of the bridge inspection vehicle according to the number of warning results and the number of failure results within the set time period includes:

[0019] Obtain a preset performance scoring table, wherein the preset performance scoring table includes performance scores corresponding to the number of warning results / number of fault results;

[0020] According to the preset performance scoring table, determining a first performance score corresponding to the number of warning results and a second performance score corresponding to the number of fault results;

[0021] Based on the first performance score and the second performance score, a performance score of the bridge inspection vehicle is obtained by summing up the scores.

[0022] Optionally, it also includes: when the performance score is lower than a set score threshold, generating a warning instruction to control the indicator light to provide a performance warning indication in a third state.

[0023] The beneficial effects of the present invention are:

[0024] According to the present invention, a bridge inspection vehicle performance evaluation and early warning system and method include a storage module, a power module, a main switch, a human-machine interface, an indicator light, an angle sensor, a motor driver and a wireless communication module, which are electrically connected to the processing module respectively; the angle sensor is used to collect the angle deviation of the synchronous walking mechanism on the left and right sides of the bridge inspection vehicle, and the processing module is used to make early warnings or fault alarms according to the angle deviation; the storage module is used to store the angle deviation data collected by the angle sensor and the early warning or fault alarm result data of the processing module; the indicator light is used to indicate the early warning or fault alarm respectively; the power module is used to supply power to each module of the bridge inspection vehicle performance evaluation and early warning system; the power module is also electrically connected to the circuit breaker, and the circuit breaker is electrically connected to the switch power supply; the motor driver is also electrically connected to the drive motor to control the speed of the drive motor, thereby realizing speed control. The performance evaluation and early warning of the inspection vehicle are realized, and the hidden safety risks existing in the use of the inspection vehicle are reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a structural schematic diagram of the bridge inspection vehicle of the present invention;

[0026] Figure 2 It is a schematic diagram of the structure of the bridge inspection vehicle performance evaluation and early warning system of the present invention;

[0027] Figure 3 It is a schematic diagram of the connection structure of the motor driver of the present invention;

[0028] Figure 4 It is a schematic diagram of the automatic deviation correction control process of the present invention;

[0029] Figure 5 It is a schematic diagram of the bridge inspection vehicle performance evaluation and early warning method of the present invention. DETAILED DESCRIPTION

[0030] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below through specific implementation methods in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0031] See also Figure 1 The specific structure of the bridge inspection vehicle is composed of tracks, truss structures, left-side walking mechanisms, right-side walking mechanisms, lifting platforms, telescopic platforms, etc. When the inspection vehicle is operating normally, the synchronous control function should work normally. Once problems occur in the processing module, drive mechanism, truss, track, angle sensor, offset switch, etc., the synchronous control function will fail.

[0032] The problem with the current control system is that it cannot monitor the operating status and performance of the synchronous control function in real time, and cannot issue early warnings for synchronous function failures, which increases the safety risk of the inspection vehicle and reduces reliability.

[0033] In this regard, the present embodiment provides a bridge inspection vehicle performance evaluation and early warning system to monitor the performance and status of the synchronous control function, and to provide early warning for possible synchronous control function failures.

[0034] See also Figure 2 The system includes a storage module, a power module, a master switch, a human-machine interface, an indicator light, an angle sensor, a motor driver and a wireless communication module, which are electrically connected to the processing module respectively; the master switch is used to control the issuance of control instructions; the angle sensor is used to collect the angle deviation of the synchronous walking mechanism on the left and right sides of the bridge inspection vehicle, and the processing module is used to issue an early warning or a fault alarm according to the angle deviation; the storage module is used to store the angle deviation data collected by the angle sensor and the early warning or fault alarm result data of the processing module; the indicator light is used to indicate the early warning or fault alarm respectively; the power module is used to supply power to each module of the performance evaluation and early warning system of the bridge inspection vehicle; the power module is also electrically connected to the circuit breaker, and the circuit breaker is electrically connected to the switch power supply; the motor driver is also electrically connected to the drive motor to control the speed of the drive motor, thereby realizing speed control.

[0035] Optionally, the system further includes an offset limit switch, which is electrically connected to the processing module and is used to trigger the offset limit switch when the deflection angle of the left and right synchronous walking mechanisms of the bridge inspection vehicle exceeds the limit angle, so as to stop the left and right synchronous walking mechanisms from continuing to operate; specifically, when the deviation angle exceeds 3 degrees, the offset limit switch will be triggered, and the processing module will stop the operation of the corresponding motor driver at this time to achieve the purpose of automatic deviation correction. The processing module is also used to generate fault alarm result data when the offset limit switch is triggered; and the storage module is also used to store the fault alarm result data.

[0036] The processing module specifically includes one of a CPU central processing unit, a single chip microcomputer, a microprocessor, and a PLC control module.

[0037] The wireless communication module can select a WiFi / 4G / 5G mobile communication module to send early warning or fault alarm result data to a remote monitoring platform to achieve remote monitoring.

[0038] See also Figure 3The motor driver includes a left motor driver and a right motor driver, and the drive motor includes a left drive motor and a right drive motor. The left motor driver is electrically connected to the left drive motor to control the rotation speed of the left drive motor, thereby realizing speed control of the synchronous walking mechanism on the left side of the bridge inspection vehicle; the right motor driver is electrically connected to the right drive motor to control the rotation speed of the right drive motor, thereby realizing speed control of the synchronous walking mechanism on the right side of the bridge inspection vehicle. The synchronization method is not limited to using an angle sensor, and a displacement sensor can also be used to measure the displacement difference between the left and right walking mechanisms, and the purpose of synchronization can be achieved by adjusting the displacement difference on both sides within a set range.

[0039] See also Figure 4 , is the automatic deviation correction control process of this system. The processing module can detect the deflection angle of the left and right synchronous walking mechanisms through the angle sensor, and calculate the angle fluctuation rate according to the set angle target. If the angle fluctuation rate is greater than the set value, the processing module will adjust the operating frequency of the left and right motor drivers through RS485 communication, and control the speed of the left and right drive motors to achieve the purpose of automatic deviation correction. However, after automatic deviation correction, if the angle fluctuation rate is still above the warning threshold or fault threshold, the processing module will generate a warning result or a fault result. For details, please refer to Figure 5 The performance evaluation and early warning method based on the system shown includes:

[0040] S501, using an angle sensor to monitor and collect the angle deviation of the synchronous walking mechanism on the left and right sides of the bridge inspection vehicle in real time;

[0041] Optionally, the detection of angle deviation is not limited to the use of angle sensors. For example, the angle deviation detection can also be achieved by measuring the difference in displacement of the left and right mechanisms.

[0042] S502, calculating the angle fluctuation rate, and comparing the angle fluctuation rate with the warning threshold and the fault threshold;

[0043] S503, when the angle fluctuation rate is lower than the warning threshold, it indicates that the bridge inspection vehicle is in normal operation;

[0044] S504: when the angle fluctuation rate is greater than or equal to the warning threshold and less than the fault threshold, a warning result is generated, and the indicator light is controlled to provide a warning indication in the first state;

[0045] Optionally, the first state is that the yellow indicator light flashes or is always on. In the early warning state, the detection vehicle can run at a low speed without stopping.

[0046] S505: When the angle fluctuation rate is greater than or equal to the fault threshold, a fault result is generated, and the indicator light is instructed to indicate the fault in the second state.

[0047] The fault threshold is higher than the warning threshold; the second state is that the red indicator light flashes or stays on. The fault state detection vehicle will automatically stop running to avoid major accidents.

[0048] S506, storing the early warning or fault alarm result data in a memory;

[0049] Optionally, the memory can be integrated into the black box to obtain and store all operating data during the operation of the inspection vehicle, so as to facilitate accident cause analysis and responsibility tracing when an operating failure or safety accident occurs.

[0050] S507, according to the set time period, regularly obtain the warning result data and fault result data generated within the set time period from the memory;

[0051] The set time period can be flexibly set according to the actual situation, for example, 5 minutes, 30 minutes, 1 hour, 1 day, etc. The set time period can be flexibly set according to the actual situation, including one of the last day, the last three days, the last week, and the last month.

[0052] S508, counting the number of warning results and the number of fault results within a set period;

[0053] S509, calculating the performance score of the bridge inspection vehicle according to the number of warning results and the number of failure results within the set time period;

[0054] Specifically, to obtain the preset performance score table, please refer to the following Table 1:

[0055] Table 1

[0056]

[0057]

[0058] The preset performance scoring table includes performance scores corresponding to each of the warning result times / fault result times. According to the preset performance scoring table, a first performance score corresponding to the warning result times and a second performance score corresponding to the fault result times are determined. Based on the first performance score and the second performance score, a performance score of the bridge inspection vehicle is obtained by summing up and calculating.

[0059] In an optional embodiment of the present invention, the abnormality frequency may be calculated according to the number of warning results and the number of fault results within a set period of time, and then the performance score of the bridge inspection vehicle may be calculated according to the abnormality frequency.

[0060] For example, the actual running time T of the bridge inspection vehicle in the past three days is obtained, and according to the weight parameters of the warning result and the fault result, assuming they are a1 and a2 respectively, the number of abnormalities k=p1*a1+p2*a2 is calculated, where p1 is the number of warning results and p2 is the number of fault results; the ratio of the number of abnormalities to the actual running time k / T is taken as the abnormal frequency, and then the performance score of the bridge inspection vehicle is calculated based on the abnormal frequency. The higher the abnormal frequency, the lower the performance score. When it is higher than the maximum threshold, the score may be 0. When the abnormal frequency is 0, the corresponding score is the highest; the highest score can be flexibly set according to the actual situation, for example, 100 points.

[0061] In an optional embodiment of the present invention, the performance score is calculated by the fluctuation rate β (%) of the angle according to the closed-loop control principle.

[0062] The calculation formula for volatility β is as follows:

[0063]

[0064] In the formula, The angle deviation of the synchronous walking mechanism on the left and right sides of the bridge inspection vehicle during synchronous operation; R S is the target angle, usually set to 90 degrees.

[0065] In other embodiments of the present invention, the performance evaluation may also be determined by the angle recovery time T(S), and the calculation formula of the angle recovery time T is as follows:

[0066] T=t2-t1

[0067] Wherein, t1 is the instant when the angle exceeds the set angle fluctuation envelope width, unit: S; t2 is the instant when the angle returns to and remains within the set angle fluctuation envelope width, unit: S.

[0068] Optionally, determine whether the fluctuation rate of the angle exceeds the warning threshold. If it exceeds the warning threshold, output the warning result information; if it exceeds the fault threshold, output the fault result information. At the same time, determine whether the angle recovery time exceeds the time warning threshold. If it exceeds the time warning threshold, output the warning result information; if it exceeds the time fault threshold, output the fault result information.

[0069] S510, sending the performance score to the human-machine interface in real time for display, and remotely sending it to the remote monitoring platform to achieve remote monitoring.

[0070] Optionally, when the performance score is lower than the set score threshold, a warning instruction is generated, and the control indicator light is controlled to provide a performance warning indication in the third state to prompt maintenance personnel to inspect and maintain the electrical system or mechanical system of the inspection vehicle, and send it to the remote monitoring platform.

[0071] On the one hand, this solution can display the operating performance and status of the synchronous control function through the human-machine interface of this system, and can also send the corresponding data to the remote monitoring cloud platform through the wireless communication module to achieve remote monitoring. In this way, relevant information can be provided to the inspection vehicle operator, and the relevant management unit can be given monitoring capabilities. At the same time, timely maintenance and repair of the inspection vehicle can be achieved through fault warning, reducing the probability of failure and improving reliability.

[0072] Obviously, those skilled in the art should understand that the modules or steps of the present invention described above can be implemented by a general-purpose computing device, they can be concentrated on a single computing device, or distributed on a network composed of multiple computing devices, and optionally, they can be implemented by a program code executable by a computing device, so that they can be stored in a computer storage medium (ROM / RAM, magnetic disk, optical disk) and executed by the computing device, and in some cases, the steps shown or described can be executed in a different order than that here, or they can be made into individual integrated circuit modules, or multiple modules or steps therein can be made into a single integrated circuit module for implementation. Therefore, the present invention is not limited to any specific combination of hardware and software.

[0073] The above contents are further detailed descriptions of the present invention in combination with specific implementation methods, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as falling within the protection scope of the present invention.

Claims

1. A method for a bridge inspection vehicle performance evaluation and early warning system, using the bridge inspection vehicle performance evaluation and early warning system, the system includes a storage module, a power module, a main switch, a human-machine interface, an indicator light, an angle sensor, a motor driver and a wireless communication module, which are electrically connected to the processing module respectively; the angle sensor is used to collect the angle deviation of the synchronous walking mechanism on the left and right sides of the bridge inspection vehicle, and the processing module is used to make an early warning or a fault alarm according to the angle deviation; the storage module is used to store the angle deviation data collected by the angle sensor and the early warning or fault alarm result data of the processing module; the indicator light is used to indicate the early warning or fault alarm respectively; the power module is used to supply power to each module of the bridge inspection vehicle performance evaluation and early warning system; the power module is also electrically connected to the circuit breaker, and the circuit breaker is electrically connected to the switching power supply; the motor driver is also electrically connected to the drive motor to control the rotation speed of the drive motor, thereby realizing speed control; It also includes an offset limit switch, which is electrically connected to the processing module and is used to trigger the offset limit switch when the deflection angle of the left and right synchronous walking mechanisms of the bridge inspection vehicle exceeds the limit angle, so as to stop the left and right synchronous walking mechanisms from continuing to operate; at this time, the processing module is also used to generate fault alarm result data; the storage module is also used to store the fault alarm result data; The processing module includes one of a CPU central processing unit, a single chip microcomputer, a microprocessor, and a PLC control module; The motor driver includes a left motor driver and a right motor driver, the drive motor includes a left drive motor and a right drive motor, the left motor driver is electrically connected to the left drive motor, and is used to control the rotation speed of the left drive motor, so as to realize the speed control of the left synchronous walking mechanism of the bridge inspection vehicle; the right motor driver is electrically connected to the right drive motor, and is used to control the rotation speed of the right drive motor, so as to realize the speed control of the right synchronous walking mechanism of the bridge inspection vehicle; The wireless communication module includes a WiFi / 4G / 5G mobile communication module, which is used to send the early warning or fault alarm result data to a remote monitoring platform to achieve remote monitoring, and is characterized in that: include: Angle sensors are used to monitor and collect the angle deviations of the synchronous walking mechanisms on the left and right sides of the bridge inspection vehicle in real time, and the angle fluctuation rate is calculated. The angle fluctuation rate is compared with the warning threshold and the fault threshold. When the angle fluctuation rate is lower than the warning threshold, it indicates that the bridge inspection vehicle is in normal operation. When the angle deviation is greater than or equal to the warning threshold and less than the fault threshold, a warning result is generated, and the indicator light is controlled to indicate a warning in the first state. When the angle fluctuation rate is greater than or equal to the fault threshold, a fault result is generated, and the indicator light is instructed to indicate a fault in the second state. The fault threshold is higher than the warning threshold. And store the early warning or fault alarm result data in the memory; According to the set time period, the warning result data and the fault result data generated within the set time period are regularly obtained from the memory; Counting the number of warning results and the number of fault results within the set time period; Calculating a performance score of the bridge inspection vehicle according to the number of warning results and the number of failure results within the set time period; The performance score is sent to a human-machine interface in real time for display, and is remotely sent to a remote monitoring platform to achieve remote monitoring.

2. The method according to claim 1, characterized in that The first state is a yellow indicator light, and the second state is a red indicator light.

3. The method according to claim 1, characterized in that The set time period includes one of the most recent day, the most recent three days, the most recent week, and the most recent month.

4. The method according to any one of claims 1 to 3, characterized in that: Calculating the performance score of the bridge inspection vehicle according to the number of warning results and the number of failure results within the set time period includes: Obtain a preset performance scoring table, wherein the preset performance scoring table includes performance scores corresponding to the number of warning results / number of fault results; According to the preset performance scoring table, determining a first performance score corresponding to the number of warning results and a second performance score corresponding to the number of fault results; Based on the first performance score and the second performance score, a performance score of the bridge inspection vehicle is obtained by summing up the scores.

5. The method according to claim 4, characterized in that Also includes: When the performance score is lower than the set score threshold, an early warning instruction is generated, the indicator light is controlled to provide a performance early warning indication in the third state, and the instruction is sent to the remote monitoring platform.

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