A transmission chain monitoring method and system and its application in crane

Abstract

The invention discloses a transmission chain monitoring method, a system and an application thereof in a crane. The monitoring method is used for transmission chain damage monitoring, and comprises: S01, building a monitoring database; S02, acquiring the transmission speed of the transmission chain in real time; S03, suppressing the vibration of the transmission chain in a non-motion interference area of ​​the transmission chain, and then performing ultrasonic detection on each chain link to generate ultrasonic detection data; S04, judging the ultrasonic detection data according to preset conditions to generate a judgment result; S05, obtaining the judgment result and identifying it, and when the judgment result is normal, storing the ultrasonic detection data in the monitoring database; when the judgment result is abnormal, generating and outputting early warning information, and at the same time, storing the early warning information and the ultrasonic detection data in the monitoring database; the scheme has the advantages of fast detection response speed and stable and reliable implementation, and provides a solid and reliable monitoring strategy and hardware scheme for the use monitoring of the crane's transmission chain.

Description

Technical Field

[0001] The invention relates to the technical field of monitoring the transmission components of lifting equipment, and in particular to a transmission chain monitoring method and system and application thereof in a crane. Background Art

[0002] Cranes are commonly used equipment in industrial production and transportation. The transmission chain is an important power transmission component. In the process of power transmission, it also bears huge transmission pressure. Among them, transmission chain damage is a high-risk equipment failure accident during the use of cranes, especially when the crane is lifting and transporting items. Once the transmission chain breaks or gets stuck, it will cause a greater safety risk. Although there are some solutions that specifically intervene and protect against transmission chain breaks in a timely manner, these are all measures for intervention after the event. The maintenance of the transmission chain mostly adopts a regular maintenance plan, which has a certain lag or randomness. Because the damage of the transmission chain is mostly during use, especially for some situations close to critical use, once the problem is not discovered in time during maintenance, it is very likely to cause equipment safety accidents. At present, there is no reliable technology for real-time monitoring of the transmission chain during its operation. Therefore, how to monitor the health status of the transmission chain during its operation is a very practical topic. Summary of the invention

[0003] In view of the prior art, the object of the present invention is to provide a transmission chain monitoring method and system and application thereof in a crane, which has rapid response, reliable implementation and no operational interference to the transmission chain of the crane during monitoring.

[0004] In order to achieve the above technical objectives, the technical solution adopted by the present invention is:

[0005] A transmission chain monitoring method is used for monitoring damage of a transmission chain, comprising:

[0006] S01. Build a monitoring database;

[0007] S02, acquiring the transmission speed of the transmission chain in real time;

[0008] S03, suppressing the vibration of the transmission chain in the non-motion interference area of ​​the transmission chain, and then performing ultrasonic testing on each chain link to generate ultrasonic testing data;

[0009] S04, judging the ultrasonic detection data according to preset conditions and generating a judgment result;

[0010] S05, obtaining the judgment result and identifying it,

[0011] When the result of the judgment is normal, the ultrasonic detection data is stored in the monitoring database;

[0012] When the judgment result is abnormal, an early warning message is generated and outputted, and at the same time, the early warning message and the ultrasonic detection data are stored in a monitoring database.

[0013] As a possible implementation, further, in S01, the monitoring database further stores a reference data set, wherein the reference data set is ultrasonic feedback waveform data of the transmission chain at different transmission speeds when the transmission chain has no abnormal damage;

[0014] S04 includes obtaining ultrasonic detection data, importing the data into a detection neural network for detection, and outputting a judgment result by the detection neural network;

[0015] The detection neural network is obtained by importing the reference data set into the neural network and training it until convergence. As a preferred implementation option, preferably, in S01, the reference data set is obtained by:

[0016] S011. Take the transmission chain, number each link of the transmission chain, and then detect the ultrasonic detection data of the transmission chain in a static state, and associate the data with the link of the corresponding number to obtain a static data set;

[0017] S012, driving the transmission chain to make it drive at a constant speed for at least 3 turns at a preset speed, and acquiring ultrasonic detection data of the transmission chain in motion in real time, then changing the driving speed of the transmission chain at a preset speed interval and continuing to acquire ultrasonic detection data after the speed is adjusted, and finally separating the acquired ultrasonic detection data, associating the separated ultrasonic detection data with the chain links with corresponding numbers, and acquiring a dynamic data set;

[0018] S013, performing mean processing on the ultrasonic detection data corresponding to each link at the same speed in the dynamic data set to generate reference ultrasonic detection data;

[0019] S014, setting upper and lower floating error values ​​for the ultrasonic detection data corresponding to each link in the static data set, and then generating ultrasonic detection data within the floating error value to obtain a first data set;

[0020] S015, setting upper and lower floating error values ​​for the ultrasonic detection data corresponding to each link in the static data set, and then generating ultrasonic detection data within the floating error value to obtain a second data set;

[0021] S016. Merge the first data set and the second data set to obtain a reference data set;

[0022] Among them, in S011, the transmission chains used include normal unused transmission chains and transmission chains with abnormal chain links. The abnormal conditions of each chain link in the transmission chain with abnormal chain links are not completely the same, and when they are numbered, the abnormal conditions of the corresponding chain links are also pre-recorded.

[0023] As a preferred implementation option, preferably, in S04, the training method of the detection neural network is: taking the ultrasonic detection data in the first data set and the second data set and the corresponding transmission speed as input items, and taking the health status of the chain link as the label information of the input items, importing the input items and the label information into the neural network together, and then training the neural network until the model converges to obtain the detection neural network;

[0024] S02 also includes: recording the duration of the transmission chain at different transmission speeds, and then obtaining the transmission stroke of the transmission chain during a single continuous use based on the duration and the corresponding transmission speed statistics, and uploading the transmission stroke to the monitoring database according to preset conditions, and the monitoring database adds up to obtain the cumulative usage stroke of the transmission chain.

[0025] As a preferred implementation option, preferably, in S05, when the judgment result is normal, the ultrasonic detection data is stored in the monitoring database, and then the accumulated use stroke of the transmission chain is also associated with it;

[0026] When the judgment result is abnormal, the ultrasonic detection data is matched with the ultrasonic detection data corresponding to the abnormal link in the reference data set, and the ultrasonic detection data corresponding to the abnormal link with the highest matching degree and the corresponding abnormal link are packaged together with the real-time ultrasonic detection data, and warning information is generated and output. At the same time, the warning information and the ultrasonic detection data are stored in the monitoring database;

[0027] The output ultrasonic detection data are all output in the form of waveform graphs.

[0028] As a preferred implementation option, preferably, S04 further includes: setting the first data set and the second data set as original data sets;

[0029] S05 further includes: after storing the ultrasonic detection data with normal judgment results and abnormal judgment results in the monitoring database, associating the judgment results with the data, and then setting them as the tuning data set;

[0030] The monitoring method further comprises:

[0031] S06. Import the tuning data set into the detection neural network for tuning training at a preset time frequency until the model converges, and then import the original data set into the detection neural network for tuning verification. When the tuning verification result meets the preset requirements, the tuning training is completed. If it does not meet the preset requirements, continue to import the tuning data set into the detection neural network to continue the tuning training until the model converges and the tuning verification result meets the preset requirements, and then the tuning training is completed.

[0032] As a preferred implementation option, preferably, S06 also includes: removing the tuning data in the tuning data set that has been imported into the detection neural network and has completed the tuning training from the tuning data set, and marking it as trained monitoring data.

[0033] Based on the above technical solution, the present invention also provides a transmission chain monitoring system, which includes:

[0034] Backend server, used to build monitoring database;

[0035] Speed ​​monitoring unit, used to obtain the transmission speed of the transmission chain in real time;

[0036] Shaping unit, used to suppress the vibration of the transmission chain in the non-motion interference area of ​​the transmission operation;

[0037] The ultrasonic flaw detection unit is used to perform ultrasonic real-time detection on each link of the transmission chain after the shaping process by the shaping unit, and generate ultrasonic detection data;

[0038] A data processing unit, used to judge the ultrasonic detection data according to preset conditions and generate a judgment result;

[0039] The data scheduling unit is used to obtain and identify the judgment results, and output warning information according to preset requirements and / or store the ultrasonic detection data in the monitoring database.

[0040] As a preferred implementation option, preferably, the shaping unit includes:

[0041] A connecting frame is fixedly arranged in a non-motion interference area of ​​the transmission chain, and an accommodating cavity is formed on the upper part of the connecting frame. Both horizontal ends of the accommodating cavity are open structures and are respectively set as an input end and an output end, and the transmission chain passes through the input end and the output end of the accommodating cavity;

[0042] The limiting mechanism is a pair and is respectively arranged at the input end and the output end of the accommodating cavity, and the limiting mechanism includes:

[0043] The first movable rods are a pair and are slidably disposed on the upper and lower ends of the accommodating cavity of the connecting frame. The first movable rods are each provided with a first external thread. The first movable rods are provided with a first extension portion at the ends outside the accommodating cavity. The connecting frame portions at the upper and lower ends of the accommodating cavity are correspondingly provided with first avoidance holes for the first movable rods to slide through;

[0044] A first limiting plate is fixed to the end of the first movable rod inserted into the accommodating cavity, and the edge of the end surface of the first limiting plate away from the first movable rod is an arc surface;

[0045] A first nut, threadedly connected to a first external thread of the first movable rod located outside the accommodating cavity;

[0046] A first spring is sleeved on the first movable rod and has one end abutting against the first limit plate and the other end abutting against the inner wall of the accommodating cavity, so as to constrain and fix the first movable rod;

[0047] The second movable rods are a pair and are slidably disposed on both sides of the receiving cavity of the connecting frame. The second movable rods are each provided with a second external thread. The second movable rods are provided with a second extension portion at the ends outside the receiving cavity. The connecting frame parts on both sides of the receiving cavity are correspondingly provided with second avoidance holes for the second movable rods to slide through.

[0048] A second limiting plate is fixed to the end of the second movable rod inserted into the accommodating cavity, and the edge of the end surface of the second limiting plate away from the second movable rod is an arc surface;

[0049] A second nut, threadedly connected to a second external thread of the second movable rod located in the accommodating cavity;

[0050] A second spring is sleeved on the second movable rod and has one end abutting against the second extension portion and the other end abutting against the outer wall of the connecting frame, thereby constraining and fixing the second movable rod;

[0051] The first limiting plates on the pair of first movable rods and the second limiting plates on the pair of second movable rods are enclosed to form a vibration suppression area, and the transmission chain passes through the vibration suppression area;

[0052] In addition, the detection end of the ultrasonic flaw detection unit penetrates between the input end and the output end of the accommodating cavity, and the detection end of the ultrasonic flaw detection unit is facing one side of the transmission chain inserted into the accommodating cavity and is used to perform ultrasonic real-time detection on each link of the transmission chain after vibration suppression treatment.

[0053] Based on the above scheme, the present invention also provides a method for monitoring the use status of a crane transmission chain, which includes the transmission chain monitoring method described above.

[0054] By adopting the above-mentioned technical scheme, compared with the prior art, the present invention has the following beneficial effects: the present scheme cleverly introduces a detection neural network to process ultrasonic detection data. The use of the trained detection neural network can greatly improve the detection efficiency, reduce manpower expenditure and improve the detection response speed, and provide a solid and reliable monitoring strategy for transmission chain detection; and when the transmission chain is subjected to ultrasonic detection, vibration suppression is also performed by the shaping unit, which helps to improve the reliability and stability of the ultrasonic detection data of the transmission chain to be detected, and avoids the vibration generated by the transmission chain during detection affecting the accuracy of the ultrasonic detection data. In addition, in addition to constructing a reference data set as training material for training the neural network, the present scheme further adds a step for data feedback training. By using the real-time transmission chain ultrasonic detection data as training material for neural network tuning, it helps to further optimize the accuracy and precision of the detection neural network, making it more in line with actual usage scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments:

[0056] Figure 1 A schematic diagram of a brief implementation process of the monitoring method of the present invention;

[0057] Figure 2 It is a schematic diagram of a brief implementation process of the monitoring method of the present invention for constructing a reference data set;

[0058] Figure 3 It is a brief implementation diagram of the monitoring system of the present invention;

[0059] Figure 4 It is a schematic diagram of the coordinated implementation structure of the shaping unit and the ultrasonic flaw detection unit of the monitoring system of the present invention;

[0060] Figure 5 for Figure 4 A schematic diagram of the enlarged local structure at point A in the middle;

[0061] Figure 6 yes Figure 4 A magnified schematic diagram of the local structure at B in the middle;

[0062] Figure 7 It is a schematic diagram of the implementation structure of the limit assembly in the shaping unit of the system of the present invention;

[0063] Figure 8 It is a schematic diagram of the setting position of the ultrasonic flaw detection unit of the system of the present invention within the plastic structure. DETAILED DESCRIPTION

[0064] like Figure 1 to Figure 2 As shown, the present invention provides a transmission chain monitoring method for monitoring the damage of the transmission chain, which includes:

[0065] S01. Build a monitoring database;

[0066] S02, acquiring the transmission speed of the transmission chain in real time;

[0067] S03, suppressing the vibration of the transmission chain in the non-motion interference area of ​​the transmission chain, and then performing ultrasonic testing on each chain link to generate ultrasonic testing data;

[0068] S04, judging the ultrasonic detection data according to preset conditions and generating a judgment result;

[0069] S05, obtaining the judgment result and identifying it,

[0070] When the result of the judgment is normal, the ultrasonic detection data is stored in the monitoring database;

[0071] When the judgment result is abnormal, an early warning message is generated and outputted, and at the same time, the early warning message and the ultrasonic detection data are stored in a monitoring database.

[0072] In the present solution S01, the monitoring database further stores a reference data set, which is ultrasonic feedback waveform data of the transmission chain at different transmission speeds when the transmission chain has no abnormal damage;

[0073] S04 includes obtaining ultrasonic detection data, importing the data into a detection neural network for detection, and outputting a judgment result by the detection neural network;

[0074] The detection neural network is obtained by importing the reference data set into the neural network and training it until convergence.

[0075] Specifically preferably, in S01, the method for obtaining the reference data set is:

[0076] S011. Take the transmission chain, number each link of the transmission chain, and then detect the ultrasonic detection data of the transmission chain in a static state, and associate the data with the link of the corresponding number to obtain a static data set;

[0077] S012, driving the transmission chain to make it drive at a constant speed for at least 3 turns at a preset speed, and acquiring ultrasonic detection data of the transmission chain in motion in real time, then changing the driving speed of the transmission chain at a preset speed interval and continuing to acquire ultrasonic detection data after the speed is adjusted, and finally separating the acquired ultrasonic detection data, associating the separated ultrasonic detection data with the chain links with corresponding numbers, and acquiring a dynamic data set;

[0078] S013, performing mean processing on the ultrasonic detection data corresponding to each link at the same speed in the dynamic data set to generate reference ultrasonic detection data;

[0079] S014, setting upper and lower floating error values ​​for the ultrasonic detection data corresponding to each link in the static data set, and then generating ultrasonic detection data within the floating error value to obtain a first data set;

[0080] S015, setting upper and lower floating error values ​​for the ultrasonic detection data corresponding to each link in the static data set, and then generating ultrasonic detection data within the floating error value to obtain a second data set;

[0081] S016. Merge the first data set and the second data set to obtain a reference data set;

[0082] Among them, in S011, the transmission chains used include normal unused transmission chains and transmission chains with abnormal chain links. The abnormal conditions of each chain link in the transmission chain with abnormal chain links are not completely the same, and when they are numbered, the abnormal conditions of the corresponding chain links are also pre-recorded.

[0083] Collecting ultrasonic detection data of normal transmission chains and abnormal transmission chains under different transmission conditions as training material for neural networks helps to improve the detection accuracy and result reliability of the detection neural network.

[0084] In the present solution S04, the training method of the detection neural network is: taking the ultrasonic detection data in the first data set and the second data set and the corresponding transmission speed as input items, and taking the health status of the chain link as the label information of the input items, importing the input items and the label information into the neural network together, and then training the neural network until the model converges, thereby obtaining the detection neural network;

[0085] S02 also includes: recording the duration of the transmission chain at different transmission speeds, and then obtaining the transmission stroke of the transmission chain during a single continuous use based on the duration and the corresponding transmission speed statistics, and uploading the transmission stroke to the monitoring database according to preset conditions, and the monitoring database adds up to obtain the cumulative usage stroke of the transmission chain.

[0086] Specifically, preferably, in S05, when the judgment result is normal, the ultrasonic detection data is stored in the monitoring database, and then the accumulated use travel of the transmission chain is also associated with it;

[0087] When the judgment result is abnormal, the ultrasonic detection data is matched with the ultrasonic detection data corresponding to the abnormal link in the reference data set, and the ultrasonic detection data corresponding to the abnormal link with the highest matching degree and the corresponding abnormal link are packaged together with the real-time ultrasonic detection data, and warning information is generated and output. At the same time, the warning information and the ultrasonic detection data are stored in the monitoring database;

[0088] The output ultrasonic detection data are all output in the form of waveform graphs.

[0089] Since the original training data is fixed in most cases, in the above scheme, the detection accuracy of the detection neural network has certain fixed limitations. In order to further adapt the detection neural network to different application scenarios and transmission chain conditions, it is preferred that S04 further includes: setting the first data set and the second data set as the original data set;

[0090] S05 further includes: after storing the ultrasonic detection data with normal judgment results and abnormal judgment results in the monitoring database, associating the judgment results with the data, and then setting them as the tuning data set;

[0091] The monitoring method further comprises:

[0092] S06. Import the tuning data set into the detection neural network for tuning training at a preset time frequency until the model converges, and then import the original data set into the detection neural network for tuning verification. When the tuning verification result meets the preset requirements, the tuning training is completed. If it does not meet the preset requirements, continue to import the tuning data set into the detection neural network to continue the tuning training until the model converges and the tuning verification result meets the preset requirements, and then the tuning training is completed.

[0093] As a preferred implementation option, preferably, S06 also includes: removing the tuning data in the tuning data set that has been imported into the detection neural network and has completed the tuning training from the tuning data set, and marking it as trained monitoring data.

[0094] Based on the technologies of S01 to S05, this solution further adds S06 for data feedback training. By using the real-time transmission chain ultrasonic detection data as training material for tuning, it helps to further optimize the accuracy and precision of the detection neural network, making it more suitable for actual usage scenarios.

[0095] like Figure 3 As shown, based on the above technical solution, this solution also provides a transmission chain monitoring system, which includes:

[0096] Backend server, used to build monitoring database;

[0097] Speed ​​monitoring unit, used to obtain the transmission speed of the transmission chain in real time;

[0098] Shaping unit, used to suppress the vibration of the transmission chain in the non-motion interference area of ​​the transmission operation;

[0099] The ultrasonic flaw detection unit is used to perform ultrasonic real-time detection on each link of the transmission chain after the shaping process by the shaping unit, and generate ultrasonic detection data;

[0100] A data processing unit, used to judge the ultrasonic detection data according to preset conditions and generate a judgment result;

[0101] The data scheduling unit is used to obtain and identify the judgment results, and output warning information according to preset requirements and / or store the ultrasonic detection data in the monitoring database.

[0102] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0103] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions for a computer device (which can be a personal computer, server, or network device, etc.) or a processor (processor) to perform all or part of the steps of each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk and other media that can store program codes.

[0104] exist Figure 3 Based on Figures 4 to 8 As shown in one of the embodiments, in this solution, the shaping unit 1 includes:

[0105] The connecting frame 11 is fixedly arranged in the non-motion interference area of ​​the transmission chain 3. The upper part of the connecting frame 11 forms a receiving cavity 111. Both horizontal ends of the receiving cavity 111 are open structures and are respectively set as an input end 112 and an output end 113. The transmission chain 3 passes through the input end 112 and the output end 113 of the receiving cavity 111.

[0106] The limiting assembly 12 is a pair and is respectively arranged at the input end 112 and the output end 113 of the accommodating cavity 111. The limiting assembly 12 includes:

[0107] The first movable rods 121 are a pair and are slidably disposed on the upper and lower ends of the accommodating cavity 111 of the connecting frame 11. The first movable rods 121 are each provided with a first external thread 1211. The first movable rods 121 are provided with a first extension portion 1212 at the ends outside the accommodating cavity 111. The connecting frame 11 parts at the upper and lower ends of the accommodating cavity 111 are correspondingly provided with first avoidance holes 114 for the first movable rods 121 to slide through.

[0108] The first limiting plate 123 is fixed to the end of the first movable rod 121 that penetrates into the accommodating cavity 111, and the end surface edge of the first limiting plate 123 away from the first movable rod 121 is an arc surface;

[0109] A first nut, threadedly connected to a first external thread 1211 of the first movable rod 121 outside the accommodating cavity 111;

[0110] The first spring 122 is sleeved on the first movable rod 121 and has one end abutting against the first limiting plate 123 and the other end abutting against the inner wall of the accommodating cavity 111, thereby constraining and fixing the first movable rod 121;

[0111] The second movable rods 124 are a pair and are slidably disposed on both horizontal sides of the accommodating cavity 111 of the connecting frame 11. The second movable rods 124 are each provided with a second external thread 1241. The second movable rods 124 are provided with a second extension portion 1242 at the ends outside the accommodating cavity 111. The connecting frame 11 portions on both horizontal sides of the accommodating cavity 111 are correspondingly provided with second avoidance holes for the second movable rods 124 to slide through.

[0112] The second limiting plate 125 is fixed to the end of the second movable rod 124 that penetrates into the accommodating cavity 111, and the end surface edge of the second limiting plate 125 away from the second movable rod 124 is an arc surface;

[0113] A second nut 127, threadedly connected to the second external thread 1241 of the second movable rod 124 located in the accommodating cavity 111;

[0114] The second spring 126 is sleeved on the second movable rod 124 and has one end abutting against the second extension portion 1242 and the other end abutting against the outer wall of the connecting frame 11, thereby constraining and fixing the second movable rod 124;

[0115] The first limiting plates 123 on the pair of first movable rods 121 and the second limiting plates 125 on the pair of second movable rods 124 are enclosed to form a vibration suppression area 128, and the transmission chain 3 passes through the vibration suppression area; in this solution, the spacing of the vibration suppression area 128 in the horizontal and vertical directions can be adjusted by rotating the first nut and the second nut 127 to achieve the suppression of vibration or shaking of the transmission chain 3 in the horizontal and vertical directions;

[0116] In addition, the detection end 211 of the ultrasonic flaw detection unit 2 penetrates between the input end 112 and the output end 113 of the accommodating cavity 111, and the detection end 211 of the ultrasonic flaw detection unit 2 is facing the side of the transmission chain 3 inserted into the accommodating cavity 111 and is used to perform ultrasonic real-time detection of each link of the transmission chain 3 after vibration suppression treatment.

[0117] Since the transmission chain 3 will adhere to the debris of mechanical matching wear and dust in the air during transmission work, causing stains to adhere to the surface of the chain link, these interference factors will affect the detection accuracy of the ultrasonic flaw detection unit 2 to a certain extent and cause a certain degree of deviation in the detection data, thereby causing the problem of reduced data reference. In order to overcome this problem, in this solution, as a preferred embodiment, the device further includes:

[0118] A lubricating medium container 4, used for storing lubricating oil;

[0119] The first oil pump 5 is arranged on the connecting frame 11, and its input end is connected to the pipeline of the lubricating medium container 4, and its output end is connected to the first nozzle 51, and the liquid output end of the first nozzle 51 extends to the upper part of the transmission chain 3 between the input end 112 of the accommodating cavity 111 and the ultrasonic flaw detection unit 2, and the first oil pump 5 sprays the lubricating oil in the lubricating medium container 4 to the transmission chain 3 through the first nozzle 51;

[0120] The first air pump 6 is arranged on the connecting frame 11, the input end of which is connected to the outside, and the output end of which is connected to the first air nozzle 61, and the gas output end of the first air nozzle 61 extends to the top of the transmission chain 3 between the first nozzle 51 and the ultrasonic flaw detection unit 2, and the first air pump 6 sprays the external air to the transmission chain 3 through the first air nozzle 61;

[0121] A controller, connected to the first oil pump 5 and the first air pump 6 and used to control the opening and closing of the first oil pump 5 and the first air pump 6;

[0122] Among them, the angle α formed between the first nozzle 51 and the transmission chain 3 is 45 to 60 degrees, and the output end of the first nozzle 51 is a flat opening, and the lubricating oil sprayed therefrom can cover the lateral area (i.e., the thickness direction) of the transmission chain 3, and the spraying pressure of the first nozzle 51 can be 0.01 to 0.05 MPa, preferably 0.03 MPa. The reason is that when the first nozzle 51 sprays the lubricating oil, it acts on the transmission chain 3, and when the transmission chain 3 is subjected to force, its vibration amplitude will increase with the increase of the force. Therefore, once the spraying pressure of the first nozzle 51 exceeds 0.05 MPa, the transmission chain 3 may vibrate significantly due to the force applied to the transmission chain 3, thereby affecting the subsequent detection by the ultrasonic flaw detection unit 2. If it is less than 0.01 MPa, it may Because the output force is too small, the lubricating oil cannot be sprayed onto the transmission chain 3 at a specific angle, and the spraying angle directly affects the angle at which the lubricating oil reaches the transmission chain 3. If it is greater than 60 degrees, the lubricating oil may be vertically sputtered when it acts on the surface of the transmission chain 3 due to the high verticality. If it is less than 45 degrees, the lubricating oil may be unable to be force-peeled off after it contacts the transmission chain 3 due to the small angle. The angle β formed between the first air nozzle 61 and the transmission chain 3 is 45 to 60 degrees, which is also based on the force considerations. It is mainly to facilitate air washing of the transmission chain 3 stained with lubricating oil and to form an air curtain to prevent the transmission chain 3 with more lubricating oil from entering the detection area of ​​the ultrasonic flaw detection unit 2, and the first air nozzle 61 is also a flat opening structure.

[0123] Since the first air pump 6 blows away most of the lubricating oil on the transmission chain 3, the transmission chain 3 may be insufficiently lubricated. In order to avoid this situation, in this solution, as a preferred embodiment, the device further includes:

[0124] The second oil pump 7 is arranged on the connecting frame 11, and its input end is connected to the pipeline of the lubricating medium container 4, and its output end is connected to the second nozzle 71, and the liquid output end of the second nozzle 71 extends to the top of the transmission chain 3 between the output end of the accommodating cavity 111 and the ultrasonic flaw detection unit 2, and the second oil pump 7 sprays the lubricating oil in the lubricating medium container 4 to the transmission chain 3 through the second nozzle 71;

[0125] Wherein, the second oil pump 7 is also connected to the controller and is turned on and off by the controller;

[0126] In addition, the angle γ formed between the second nozzle 71 and the transmission chain 3 is 45 to 60 degrees, and the angle selection is also based on the first nozzle 51. Similarly, the spray pressure of the second nozzle 71 can be 0.01 to 0.05 MPa, preferably 0.03 MPa.

[0127] Under this structural scheme, the main function of the lubricating oil sprayed onto the transmission chain 3 by the first nozzle 51 is to clean the lubricating oil. In addition, the first air nozzle 61 performs air blowing, which helps to improve the cleanliness of the surface of the transmission chain 3. The second nozzle 71 sprays the lubricating oil onto the transmission chain 3 in order to prevent rust on the transmission chain 3 and improve the lubrication of the mechanical fit, thereby reducing wear and increasing the service life.

[0128] In ultrasonic testing, the ultrasonic flaw detection unit 2 described in this solution includes:

[0129] The ultrasonic detection probe 21 has a detection end 211 which penetrates into the connecting frame 11 from one side of the connecting frame 11 and is used to output detection ultrasonic waves and receive feedback ultrasonic waves that are reflected back;

[0130] The baffle 22 is arranged in the accommodating cavity 111 and opposite to the detection end of the ultrasonic detection probe 21. The end face of the baffle 22 away from the ultrasonic detection detection is fixed to the connecting frame 11 through a connecting rod 23. A detection area 24 for passing through the transmission chain 3 is formed between the ultrasonic detection probe 21 and the baffle 22. In this scheme, the main function of the baffle 22 is to provide a feedback limit or mark for the cutoff of the detection waveform. Because the position of the baffle 22 is fixed, when the detection ultrasonic wave output by the ultrasonic detection probe 21 propagates to the baffle 22, the feedback ultrasonic wave is received, and the waveform data generated is a fixed position or close to a fixed position (the propagation distance and speed are fixed). Therefore, the existence of the baffle 22 helps to separate the detection data and avoid other irregular non-detection objects from causing data interference (i.e. noise) to the detection results.

[0131] The lubricating oil is sprayed onto the transmission chain 3 through the first oil pump 5, which will more or less cause a small amount of lubricating oil to drip when the transmission chain 3 moves to the detection area 24. In order to facilitate its removal and guidance, in this scheme, as a preferred implementation method, further, the accommodating cavity 111 corresponds to the ultrasonic flaw detection unit 2 and is further provided with a bracket 116, and the bracket 116 is a concave structure, and the upper end surface edges of the concave structure are all arc-shaped transitions.

[0132] Since there may be excess lubricating oil when the first oil pump 5 and the second oil pump 7 apply lubricating oil to the transmission chain 3, in order to avoid waste and pollution of the working area of ​​the equipment, in this solution, as a preferred embodiment, the device further includes:

[0133] The first recovery cylinder 8 is a conical cylindrical structure with two ends open, with its large end facing upward and vertically arranged between the bracket 116 and the input end of the accommodating chamber 111 and opposite to the first nozzle 51 and the first air nozzle 61. The transmission chain 3 spans over the large end of the first recovery cylinder 8, and the small end of the first recovery cylinder 8 is provided with a first electric control valve 81;

[0134] The first transfer box 82 is arranged side by side on one side of the first recovery tube 8, and its upper end is not higher than the upper end surface of the first recovery tube 8. The first transfer box 82 and the first recovery tube 8 are connected through a first ∩-shaped tube 83, wherein one end of the first ∩-shaped tube 83 penetrates into the first recovery tube 8 and extends to the middle of the first recovery tube 8, and the other end of the first ∩-shaped tube 83 penetrates into the first transfer box 82 and extends to the upper part of the first transfer box 82. In addition, the ∩-shaped turning part of the first ∩-shaped tube 83 penetrates the upper part of the first recovery tube 8 and is not higher than the upper end of the first recovery tube 8;

[0135] A first pump 85, whose input end is connected to the small opening end of the first recovery cylinder 8 through a first pipeline 851 and is used to output the solid-liquid mixture precipitated at the lower end of the first recovery cylinder 8;

[0136] The second recovery cylinder 9 is a conical cylindrical structure with two ends open, with its large end facing upward and vertically arranged between the bracket 116 and the output end of the accommodating chamber 111 and opposite to the second nozzle 71, the transmission chain 3 spans over the large end of the second recovery cylinder 9, and the small end of the second recovery cylinder 9 is provided with a second electric control valve 91;

[0137] The second transfer box 92 is arranged side by side on one side of the second recovery tube 9, and its upper end is not higher than the upper end surface of the second recovery tube 9. The second transfer box 92 and the second recovery tube 9 are connected through a second ∩-shaped tube 93, wherein one end of the second ∩-shaped tube 93 penetrates into the second recovery tube 9 and extends to the middle of the second recovery tube 9, and the other end of the second ∩-shaped tube 93 penetrates into the second transfer box 92 and extends to the upper part of the second transfer box 92. In addition, the ∩-shaped turning part of the second ∩-shaped tube 93 penetrates the upper part of the second recovery tube 9 and is not higher than the upper end of the second recovery tube 9;

[0138] A second pump 95, whose input end is connected to the small opening end of the second recovery cylinder 9 through a second pipeline and is used to output the solid-liquid mixture precipitated at the lower end of the second recovery cylinder 9;

[0139] The sediment recovery tank 10 is connected to the output end pipelines of the first pump 85 and the second pump 95 respectively and is used to store the solid-liquid mixture transported by the first pump 85 and the second pump 95;

[0140] The bottom of the concave structure of the bracket 116 is provided with an arc-shaped arched portion 1162, and the bottom of the concave structure of the bracket 116 close to the first recovery tube 8 and the side of the second recovery tube 9 are both inclinedly provided with liquid guide grooves 1161;

[0141] In addition, the first electrically controlled valve 81, the second electrically controlled valve 91, the first pump 85 and the second pump 95 are all connected to the controller and are opened and closed by the controller.

[0142] This solution cleverly utilizes the siphon principle and sets a first ∩-shaped tube 83 and a second ∩-shaped tube 93 to pump the relatively clear lubricating liquid accumulated in the first recovery drum 8 and the second recovery drum 9 to the first transfer box 82 and the second transfer box 92 respectively. This method does not require the use of an external motor for active driving, and only relies on the liquid level of the communicating vessel principle to realize the timing of starting the siphon force, thereby achieving the technical effect of adaptive transfer of liquid between different containers.

[0143] Since the first transfer box 82 and the second transfer box 92 need to transfer lubricating oil after storing a certain amount to avoid exceeding the storage amount, in this solution, as a preferred embodiment, further, the lower part of the first transfer box 82 is connected to the lubricating medium container 4 through a third pipeline 891, and a third electric control valve 892 is provided on the end of the third pipeline 891 close to the first transfer box 82, and a third pump 89 is provided on the end of the third pipeline 891 close to the lubricating medium container 4;

[0144] The lower part of the second transfer box 92 is connected to the lubricating medium container 4 through a fourth pipeline 991, and a fourth electric control valve 992 is provided on the end of the fourth pipeline 991 close to the second transfer box 92, and a fourth pump 99 is provided on the end of the fourth pipeline 991 close to the lubricating medium container 4;

[0145] The third electrically controlled valve 892, the fourth electrically controlled valve 992, the third pump 89 and the fourth pump 99 are all connected to the controller and are opened and closed by the controller.

[0146] In order to make the start timing of the third pump 89 and the fourth pump 99 more flexible, and to make the adjustment of the siphon extraction height of the lubricating liquid in the first recovery tube 8 and the second recovery tube 9 more convenient, as a preferred embodiment, further, in this scheme, a first water flow sensor 88 is provided at the end of the first ∩-shaped tube 83 close to the first transfer box 82, and the first water flow sensor 88 is connected to the controller and is used to feedback the liquid flow state in the first ∩-shaped tube 83;

[0147] A second water flow sensor 98 is provided at the end of the second ∩-shaped tube 93 close to the second transfer box 92. The second water flow sensor 98 is connected to the controller and is used to feedback the flow state of the liquid in the second ∩-shaped tube 93.

[0148] A first sliding sleeve 84 is also slidably sleeved on the outer side of the end of the first ∩-shaped tube 83 that penetrates into the first transfer box 82. A first sealing ring 841 is fixedly arranged between the first sliding sleeve 84 and the first ∩-shaped tube 83. A first pull rod 86 is connected to the lower end of the first sliding sleeve 84. The lower end of the first pull rod 86 extends downward and passes through the first recovery tube 8. A first sealing member 87 is provided at the position of the first recovery tube 8 corresponding to the penetration position of the first pull rod 86. The first sliding sleeve 84 is driven by the lifting and pulling of the first pull rod 86 to slide on the end of the first ∩-shaped tube 83.

[0149] A second sliding sleeve 94 is also slidably sleeved on the outer side of the end of the second ∩-shaped tube 93 that penetrates into the second transfer box 92, and a second sealing ring 941 is fixedly arranged between the second sliding sleeve 94 and the second ∩-shaped tube 93. The lower end of the second sliding sleeve 94 is connected to a second pull rod 96, and the lower end of the second pull rod 96 extends downward and passes through the second recovery cylinder 9, and a second sealing member 97 is provided at the position of the second recovery cylinder 9 corresponding to the insertion position of the second pull rod 96. The second sliding sleeve 94 is driven by the lifting and lowering of the second pull rod 96 to slide on the end of the second ∩-shaped tube 93.

[0150] This solution cleverly uses the first water flow sensor 88 and the second water flow sensor 98 to sense the number of siphoning occurrences of the first ∩-shaped tube 83 and the second ∩-shaped tube 93, thereby indirectly estimating the lubricating fluid reserves in the first transfer box 82 and the second transfer box 92. At the same time, the controller is triggered to control the corresponding third pump 89 or the fourth pump 99 to work according to the set number of siphoning counts, so as to promptly transport the lubricating fluid in the first transfer box 82 and the second transfer box 92 to the lubricating medium container 4 for reuse. At the same time, the first pump 85 and the second pump 95 can be further controlled to pump the sediment at the bottom of the first recovery cylinder 8 and the second recovery cylinder 9 to the sediment recovery tank 10, thereby achieving temporary cleaning of the first recovery cylinder 8 and the second recovery cylinder 9.

[0151] Based on the above device, the present solution also provides a crane transmission mechanism fault monitoring method, which includes the above-mentioned crane transmission mechanism fault monitoring device, and the monitoring method includes the following steps:

[0152] (1) The monitoring terminal builds a monitoring database, which stores ultrasonic detection data of the transmission chain 3 under different health conditions and different transmission speeds;

[0153] (2) The crane starts, and the transmission chain 3 is driven by the driving force to start transmission operation;

[0154] (3) The controller controls the first oil pump 5, the second oil pump 7, the first air pump 6 and the ultrasonic flaw detection unit 2 to start working, so that the transmission chain 3 is sprayed with lubricating oil when entering the detection area, and the stains and dust remaining on the surface are washed away. The transmission chain 3 is then sprayed with air by the first air pump 6 and enters the detection area;

[0155] (4) The ultrasonic detection probe 21 of the ultrasonic flaw detection unit 2 performs ultrasonic detection on each link of the transmission chain 3 entering the detection area to obtain ultrasonic detection data, which is transmitted to the monitoring terminal for detection and judgment. When the ultrasonic detection data does not meet the preset requirements, the monitoring terminal outputs a warning signal;

[0156] (5) After the inspection, the transmission chain 3 moves out of the inspection area 24 along the transmission direction and passes through the shaping unit 1 after the second oil pump 7 sprays lubricating oil for the second time;

[0157] (6) The first recovery tube 8 continuously receives the dripping lubricant. When the lubricant level exceeds the ∩-shaped turning portion of the first ∩-shaped tube 83, the lubricant enters the first transfer box 82 and forms a siphon force to suck the lubricant whose level is higher than the lower end of the first sliding sleeve 84, so that it is passively sucked into the first transfer box 82. At the same time, the first water flow sensor 88 senses the fluid flow in the first ∩-shaped tube 83 and generates a sensing signal. The sensing signal is transmitted to the controller, which counts. When the count value reaches a preset value, the controller controls the third electric control valve 892 to open, and then controls the third pump 89 to start, so as to transport the lubricant in the first transfer box 82 to the lubricating medium container 4; the second recovery tube 9 continuously receives the dripping lubricant. When the lubricant is high, the lubricant enters the first transfer box 82 and forms a siphon force to suck the lubricant whose level is higher than the lower end of the first sliding sleeve 84, so that it is passively sucked into the first transfer box 82. At the same time, the first water flow sensor 88 senses the fluid flow in the first ∩-shaped tube 83 and generates a sensing signal. The sensing signal is transmitted to the controller, which counts. When the count value reaches a preset value, the controller controls the third electric control valve 892 to open, and then controls the third pump 89 to start, so as to transport the lubricant in the first transfer box 82 to the lubricating medium container 4. When the degree exceeds the ∩-shaped turning part of the second ∩-shaped tube 93, the lubricating liquid enters the second transfer box 92 and forms a siphon force to suck the lubricating liquid whose liquid level is higher than the lower end of the second sliding sleeve 94, so that it is passively sucked into the second transfer box 92. At the same time, the second water flow sensor 98 senses the flow of the fluid in the second ∩-shaped tube 93 and generates a sensing signal, which is transmitted to the controller, and the controller counts. When the count value reaches a preset value, the controller controls the fourth electric control valve 992 to open, and then controls the fourth pump 99 to start, so as to transport the lubricating liquid in the first transfer box 82 to the lubricating medium container 4; wherein, after the third electric control valve 892, the fourth electric control valve 992, the third pump 89 and the fourth pump 99 are started for a preset time, they are closed;

[0158] (7) The controller controls the second electrically controlled valve 91 and the third electrically controlled valve 892 to open, and then controls the first pump 85 and the second pump 95 to start, so that the solid-liquid mixture at the bottom of the first recovery cylinder 8 and the second recovery cylinder 9 is pumped to the sediment recovery tank 10 by the first pump 85 and the second pump 95, respectively. The first electrically controlled valve 81, the second electrically controlled valve 91, the first pump 85 and the second pump 95 are closed after being started for a preset time.

[0159] The above scheme suppresses the vibration of the transmission chain by setting a shaping mechanism in the non-motion interference area of ​​the transmission chain of the crane, so that the transmission chain can remain stable during ultrasonic testing, and the first oil pump and the first air pump set in the shaping mechanism can clean the transmission chain to be tested and improve the cleanliness of its surface, so that more ultrasonic testing data with reference value can be obtained during subsequent ultrasonic testing. Finally, the transmission chain after testing is passed through the second oil pump to apply lubricating oil, so that the transmission chain can be re-applied with lubricating oil in time after testing, so as to improve the service life of the transmission chain and the lubrication of the mechanical coordination. In addition, the lubricating oil dripping from the transmission chain is recovered and reused through the components of the first recovery drum and the second recovery drum, thereby avoiding the waste of lubricating oil and improving the economy of the device.

[0160] The above is an embodiment of the present invention. For ordinary technicians in this field, according to the teachings of the present invention, all equivalent changes, modifications, substitutions and variations made within the scope of the patent application of the present invention without departing from the principles and spirit of the present invention should fall within the scope of the present invention.

Claims

1. A transmission chain monitoring system, characterized in that: It includes: Backend server, used to build monitoring database; Speed ​​monitoring unit, used to obtain the transmission speed of the transmission chain in real time; Shaping unit, used to suppress the vibration of the transmission chain in the non-motion interference area of ​​the transmission operation; The ultrasonic flaw detection unit is used to perform ultrasonic real-time detection on each link of the transmission chain after the shaping process by the shaping unit, and generate ultrasonic detection data; A data processing unit, used to judge the ultrasonic detection data according to preset conditions and generate a judgment result; A data scheduling unit is used to obtain the judgment result and identify it, When the result of the judgment is normal, the ultrasonic detection data is stored in the monitoring database; When the judgment result is abnormal, a warning message is generated and output, and at the same time, the warning message and the ultrasonic detection data are stored in the monitoring database; Wherein, the shaping unit comprises: A connecting frame is fixedly arranged in a non-motion interference area of ​​the transmission chain, and an accommodating cavity is formed on the upper part of the connecting frame. Both horizontal ends of the accommodating cavity are open structures and are respectively set as an input end and an output end, and the transmission chain passes through the input end and the output end of the accommodating cavity; The limiting mechanism is a pair and is respectively arranged at the input end and the output end of the accommodating cavity, and the limiting mechanism includes: The first movable rods are a pair and are slidably disposed on the upper and lower ends of the accommodating cavity of the connecting frame. The first movable rods are each provided with a first external thread. The first movable rods are provided with a first extension portion at the ends outside the accommodating cavity. The connecting frame portions at the upper and lower ends of the accommodating cavity are correspondingly provided with first avoidance holes for the first movable rods to slide through; A first limiting plate is fixed to the end of the first movable rod inserted into the accommodating cavity, and the edge of the end surface of the first limiting plate away from the first movable rod is an arc surface; A first nut, threadedly connected to a first external thread of the first movable rod located outside the accommodating cavity; A first spring is sleeved on the first movable rod and has one end abutting against the first limit plate and the other end abutting against the inner wall of the accommodating cavity, so as to constrain and fix the first movable rod; The second movable rods are a pair and are slidably disposed on both sides of the receiving cavity of the connecting frame. The second movable rods are each provided with a second external thread. The second movable rods are provided with a second extension portion at the ends outside the receiving cavity. The connecting frame parts on both sides of the receiving cavity are correspondingly provided with second avoidance holes for the second movable rods to slide through. A second limiting plate is fixed to the end of the second movable rod inserted into the accommodating cavity, and the edge of the end surface of the second limiting plate away from the second movable rod is an arc surface; A second nut, threadedly connected to a second external thread of the second movable rod located in the accommodating cavity; A second spring is sleeved on the second movable rod and has one end abutting against the second extension portion and the other end abutting against the outer wall of the connecting frame, thereby constraining and fixing the second movable rod; The first limiting plates on the pair of first movable rods and the second limiting plates on the pair of second movable rods are enclosed to form a vibration suppression area, and the transmission chain passes through the vibration suppression area; In addition, the detection end of the ultrasonic flaw detection unit penetrates between the input end and the output end of the accommodating cavity, and the detection end of the ultrasonic flaw detection unit is facing one side of the transmission chain that penetrates into the accommodating cavity and is used to perform ultrasonic real-time detection on each link of the transmission chain after vibration suppression treatment; The ultrasonic flaw detection unit comprises: An ultrasonic detection probe, whose detection end penetrates into the connecting frame from one side of the connecting frame and is used to output detection ultrasonic waves and receive feedback ultrasonic waves that are reflected back; The baffle is arranged in the accommodating cavity and opposite to the detection end of the ultrasonic detection probe. The end face of the baffle away from the ultrasonic detection detection is fixed to the connecting frame through a connecting rod, and a detection area for passing through the transmission chain is formed between the ultrasonic detection probe and the baffle.

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