A gantry crane operation state monitoring method and monitoring system

Abstract

The application discloses a gantry crane operation state monitoring method and a monitoring system. The method comprises the following steps: acquiring load data, stress data and beam span deflection of the gantry crane; determining the maximum combined stress of a beam unit of the gantry crane and the displacement value of a node of the beam unit according to the load data; performing operation state early warning of the gantry crane according to the load data, the stress data, the beam span deflection, the maximum combined stress and the displacement value; generating a maximum combined stress cloud chart according to the maximum combined stress, generating a gantry crane deformation cloud chart according to the displacement value, displaying the maximum combined stress cloud chart, the gantry crane deformation cloud chart, the load data and the operation state early warning information on a three-dimensional model of the gantry crane. The method realizes comprehensive monitoring of the gantry crane state, improves the comprehensiveness and reliability of the operation state early warning of the gantry crane, and can more intuitively display the operation state of the gantry crane through various information visualization.

Description

Technical Field

[0001] This application relates to the field of equipment health monitoring technology, and in particular to a method and system for monitoring the operating status of a gantry crane. Background Technology

[0002] Large-scale lifting machinery (gantry cranes, bridge erecting machines, hanging baskets, etc.) is indispensable in bridge construction, serving as the operating platform for bridge construction personnel and equipment. During bridge construction, all loads, including those of construction personnel, equipment, and the weight of the concrete beams, are borne by these large lifting equipment. Only by ensuring the stability and safety of this equipment can the safety of construction personnel, equipment, and the bridge structure be guaranteed. Therefore, it is necessary to provide early warnings when abnormalities occur in the operating, working, or structural conditions of the lifting machinery during operation, prompting safety personnel and operators to take appropriate measures to ensure the safety of the machinery, bridge structure, and construction personnel.

[0003] In related technologies, when monitoring the status of large lifting equipment such as gantry cranes, the decision to issue an early warning is made solely based on sensor data from key stress-bearing parts of the gantry crane. This approach suffers from insufficient and incomplete stress measurement points for early warning, and damage to some stress or deformation sensors can also have a decisive impact on the reliability of the early warning, resulting in low reliability.

[0004] Therefore, how to comprehensively monitor the status of gantry cranes and improve the reliability of safety early warning systems are technical problems that need to be solved. Summary of the Invention

[0005] The main purpose of this application is to provide a method and system for monitoring the operating status of a gantry crane, aiming to solve the technical problem that the existing technology relies solely on sensor data from key stress-bearing parts of the gantry crane to determine whether to issue an early warning, resulting in insufficient and incomplete monitoring points for the gantry crane's status.

[0006] Firstly, this application provides a method for monitoring the operating status of a gantry crane, the method comprising the following steps:

[0007] Obtain the load data, stress data, and mid-span deflection of the crossbeam of the gantry crane;

[0008] The maximum combined stress of the beam element of the gantry crane and the displacement value of the nodes of the beam element are determined based on the load data.

[0009] The gantry crane's operating status is warned based on the load data, stress data, mid-span deflection of the crossbeam, maximum combined stress, and displacement value.

[0010] A maximum combined stress cloud map is generated based on the maximum combined stress, and a gantry crane deformation cloud map is generated based on the displacement value. The maximum combined stress cloud map and the gantry crane deformation cloud map are displayed on the three-dimensional model of the gantry crane, along with the load data and the operating status warning information.

[0011] In some embodiments, obtaining the load data, stress data, and mid-span deflection of the gantry crane includes:

[0012] The load value of the gantry crane is monitored by a side pressure tension sensor installed on the hook of the gantry crane, and the load position of the gantry crane is monitored by a photoelectric encoder installed on the overhead crane.

[0013] The stress data were monitored by surface strain gauges installed at the mid-span of the beam and the middle of the outriggers of the gantry crane, respectively.

[0014] The mid-span deflection of the beam was monitored by static level instruments installed at the leftmost end and the mid-span of the beam of the gantry crane.

[0015] In some embodiments, determining the maximum combined stress of the beam element of the gantry crane and the displacement values ​​of the nodes of the beam element based on the load data includes:

[0016] The load and boundary conditions are applied to the pre-set finite element model of the gantry crane according to the load value and the load position;

[0017] The internal forces of the beam element and the displacement values ​​of the nodes of the beam element are obtained by calculating using the finite element model of the gantry crane.

[0018] The maximum combined stress of the beam element is obtained by calculating the internal forces of the beam element.

[0019] The internal forces of the beam element include axial force, bending moment, and shear force.

[0020] In some embodiments, the step of providing an early warning of the gantry crane's operating status based on the load data, the stress data, the mid-span deflection of the beam, the maximum combined stress, and the displacement value includes:

[0021] When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective first threshold, a first-level early warning signal is issued to provide a first-level operational status warning.

[0022] When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective second thresholds, a level-two warning signal is issued to provide a level-two operational status warning.

[0023] When the load value, stress data, mid-span deflection of the crossbeam, maximum combined stress, or displacement value of the gantry crane exceed their respective third threshold, a level three warning signal is issued to provide a level three operational status warning.

[0024] The third threshold is greater than the second threshold, and the second threshold is greater than the first threshold.

[0025] In some embodiments, when the first-level warning signal, the second-level warning signal, or the third-level warning signal is turned off, if the operating status warning level is increased, a warning signal of the corresponding level is issued; if the operating status warning level is the same or decreased, no more warning signals are issued, and the operating status warning information is stored.

[0026] In some embodiments, the method further includes:

[0027] The conditions of loading the gantry crane at the mid-span of the beam, the rated lifting capacity of the gantry crane by a first preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the first threshold corresponding to the stress data and the mid-span deflection of the beam, respectively.

[0028] The conditions of loading the gantry crane at the mid-span of the crossbeam, the rated lifting capacity of the gantry crane by a second preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the second threshold corresponding to the stress data and the mid-span deflection of the crossbeam.

[0029] The loading conditions of the gantry crane being at the mid-span of the crossbeam, the rated lifting capacity of the gantry crane being a third preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the stress data and the third threshold corresponding to the mid-span deflection of the crossbeam.

[0030] In some embodiments, the method further includes: determining whether the third threshold of the mid-span deflection of the beam corresponding to the obtained mid-span deflection of the beam is greater than the preset limit threshold of the mid-span deflection of the beam;

[0031] If so, the fourth preset multiple of the beam mid-span deflection limit threshold is taken as the first threshold of beam mid-span deflection, the fifth preset multiple of the beam mid-span deflection limit threshold is taken as the second threshold of beam mid-span deflection, and the beam mid-span deflection limit threshold is taken as the third threshold of beam mid-span deflection, wherein the fifth preset multiple is greater than the fourth preset multiple.

[0032] The value of the mid-span deflection limit threshold of the crossbeam is:

[0033]

[0034] Where f is the mid-span deflection limit threshold of the crossbeam, S is the span of the gantry crane, and C is a constant parameter, which is determined according to the positioning accuracy of the gantry crane.

[0035] Secondly, this application also provides a monitoring system for the operating status of a gantry crane, the system comprising:

[0036] The data acquisition module is used to acquire the load data, stress data, and mid-span deflection of the crossbeam of the gantry crane;

[0037] The data calculation module is used to determine the maximum combined stress of the beam unit of the gantry crane and the displacement value of the nodes of the beam unit based on the load data.

[0038] The status early warning module is used to provide early warning of the operating status of the gantry crane based on the load data, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, and the displacement value.

[0039] The visualization module is used to generate a maximum combined stress cloud map based on the maximum combined stress, generate a gantry crane deformation cloud map based on the displacement value, display the maximum combined stress cloud map and the gantry crane deformation cloud map on the 3D model of the gantry crane, and display the load data and the operating status warning information.

[0040] In some embodiments, the system further includes:

[0041] A cloud-based database is used to store the load data, stress data, mid-span deflection of the beam, maximum combined stress of the beam element, and displacement values ​​of the nodes of the beam element.

[0042] In some embodiments, the data acquisition module includes:

[0043] A side-pressure tension sensor is installed on the hook of the gantry crane to monitor the load value of the gantry crane;

[0044] An optical encoder is installed on the overhead crane of the gantry crane to monitor the load position of the gantry crane;

[0045] Surface strain gauges are respectively installed at the mid-span of the crossbeam and the middle of the outrigger of the gantry crane to monitor the stress data;

[0046] A static level is installed at the leftmost end and the middle of the crossbeam of the gantry crane to monitor the deflection at the middle of the crossbeam.

[0047] This application provides a method and system for monitoring the operating status of a gantry crane. The method includes acquiring load data, stress data, and mid-span deflection of the beam of the gantry crane; determining the maximum combined stress of the beam element and the displacement value of the node of the beam element based on the load data; providing an early warning of the operating status of the gantry crane based on the load data, stress data, mid-span deflection of the beam, maximum combined stress, and displacement value; generating a maximum combined stress cloud map based on the maximum combined stress, generating a gantry crane deformation cloud map based on the displacement value, and displaying the maximum combined stress cloud map and the gantry crane deformation cloud map on a three-dimensional model of the gantry crane, as well as displaying the load data and the early warning information of the operating status. This achieves comprehensive monitoring of the gantry crane status, improves the comprehensiveness and reliability of the early warning of the gantry crane's operating status, and the visualization of various information can more intuitively display the operating status of the gantry crane. Attached Figure Description

[0048] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0049] Figure 1 A flowchart illustrating a method for monitoring the operating status of a gantry crane, provided in an embodiment of this application;

[0050] Figure 2 A schematic diagram showing the locations of sensors for a gantry crane;

[0051] Figure 3 A schematic block diagram of a gantry crane operation status monitoring system provided in this application embodiment;

[0052] Figure 4 This is a schematic diagram showing the positive direction of bending moment for a beam element.

[0053] Figure 5 This is for storing the displacement data of the nodes;

[0054] Figure 6 The maximum combined stress of the stored beam elements;

[0055] Figure 7 This is a schematic diagram of the early warning process.

[0056] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0057] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0058] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0059] This application provides a method and system for monitoring the operating status of a gantry crane.

[0060] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0061] Please refer to Figure 1 , Figure 1 This is a flowchart illustrating a method for monitoring the operating status of a gantry crane, provided as an embodiment of this application.

[0062] like Figure 1 As shown, the method includes steps S1 to S4.

[0063] Step S1: Obtain the load data, stress data, and mid-span deflection of the gantry crane beam.

[0064] Specifically, obtaining the load data, stress data, and mid-span deflection of the gantry crane includes:

[0065] The load value of the gantry crane is monitored by a side-pressure tension sensor installed on the hook of the gantry crane; the load position of the gantry crane is monitored by a photoelectric encoder installed on the overhead crane; the stress data is monitored by surface strain gauges installed at the mid-span of the crossbeam and the middle of the outriggers of the gantry crane; and the mid-span deflection of the crossbeam is monitored by static levels installed at the leftmost end and the mid-span of the crossbeam of the gantry crane.

[0066] As an example, this embodiment uses a data acquisition module composed of multiple sensors mounted on the gantry crane to obtain the gantry crane's load data, stress data, and mid-span deflection of the crossbeam. For example... Figure 2As shown, the data acquisition module includes: one lateral pressure tension sensor, positioned on the sling above the hook, used to monitor the hook's load; the monitored hook load is the load value of the gantry crane; one photoelectric encoder, positioned on the trolley, used to monitor the trolley's position on the crossbeam; the monitored trolley's position on the crossbeam is the load position of the gantry crane; five surface strain gauges, positioned at the mid-span of the crossbeam and the middle of the outriggers, used to measure the stress values ​​at these points; and two static levels, one positioned at the leftmost end of the gantry crane's crossbeam as a positional reference, and the other positioned at the mid-span of the gantry crane's crossbeam to measure the mid-span deflection value. Figure 3 As shown, the data monitored by the sensors in the data acquisition module is transmitted to the cloud database for storage via a wireless network through the data acquisition device and data transmission device in the data acquisition module.

[0067] It's worth noting that the Python pymysql sublibrary can be used on computer devices to connect to cloud databases and extract real-time data measured by sensors. Here, pymysql is the interface for connecting from Python to a MySQL database server.

[0068] Step S2: Determine the maximum combined stress of the beam unit of the gantry crane and the displacement value of the nodes of the beam unit based on the load data.

[0069] In some embodiments, determining the maximum combined stress of the beam element of the gantry crane and the displacement values ​​of the nodes of the beam element based on the load data includes:

[0070] The load and boundary conditions are applied to the pre-set gantry crane finite element model according to the load value and the load position; the internal forces of the beam element and the displacement values ​​of the nodes of the beam element are calculated through the gantry crane finite element model; the maximum combined stress of the beam element is calculated based on the internal forces of the beam element; wherein, the internal forces of the beam element include axial force, bending moment and shear force.

[0071] As an example, the data calculation module in the computer device can be used to apply loads and boundary conditions to a pre-built gantry crane finite element model based on the hook lifting weight (load value) and the position of the gantry crane on the crossbeam (loaded position) stored in the cloud database and the feon sub-library in Python. Then, the internal forces of all beam elements and the displacements of all nodes of the gantry crane can be calculated based on the gantry crane finite element model with applied loads and boundary conditions. The internal forces of the beam elements include axial force, bending moment and shear force.

[0072] Furthermore, after obtaining the internal forces of the beam elements of the gantry crane, the maximum combined stress of the beam elements is calculated based on these internal forces. For example... Figure 4 As shown, since a beam element has two nodes, I and J, the bending moments at the two cross-sections located at nodes I and J are different. Therefore, the maximum combined stress needs to be calculated separately at cross-sections I and J, and the larger absolute value is taken as the final maximum combined stress value of the beam element. The formula for calculating the maximum combined stress at cross-section I is given below:

[0073]

[0074] Among them, S MCS S is the maximum combined stress at section I. ax For the axial stress of the beam element, S by1 S by2 Bending moment M z The resulting normal stress, S bz1 S bz2 Bending moment M y The resulting normal stress.

[0075] S ax S by1 S by2 S bz1 and S bz2 The expression is as follows:

[0076]

[0077] In the formula, N is the axial force of the beam element (positive when the beam element is under tension and negative when it is under compression), and A is the cross-sectional area of ​​the beam element (the cross-sectional area of ​​the beam element remains unchanged along the local coordinate axis x-axis of the element).

[0078]

[0079] In the formula M Iz Let C be the bending moment about the z-axis on section I. yp I is the distance from the neutral axis to the edge fiber in the beam element section along the +y axis direction of the local coordinate system of the beam element. zz Let be the moment of inertia of the beam element section about the z-axis.

[0080]

[0081] In the formula C ym This represents the distance from the neutral axis to the edge fiber in the beam element section along the -y-axis direction of the local coordinate system of the beam element.

[0082]

[0083] In the formula M Iy Let C be the bending moment about the y-axis on section I. zp Let I be the distance from the neutral axis to the edge fiber in the beam element section along the +z axis direction of the local coordinate system of the beam element.yy Let be the moment of inertia of the beam element section about the y-axis.

[0084]

[0085] In the formula C zm This represents the distance from the neutral axis to the edge fiber in the cross section of the beam element along the -z-axis direction of the local coordinate system of the beam element.

[0086] It should also be noted that the local coordinate system of the beam element is a right-handed rectangular coordinate system, with the x-axis pointing from node I (the origin of the local coordinate system) to node J, and the positive direction of the bending moment as shown in the figure. Figure 4 As shown. The calculation method for section J is similar to that for section I, and will not be repeated here.

[0087] like Figure 5 As shown, all calculated node displacement data are stored in a cloud database, with the unit of node displacement being meters (m). Figure 6 As shown, the internal forces of all beam elements, including axial force, bending moment and shear force, as well as the maximum combined stress of the beam element calculated by the formula, are calculated and stored in the cloud database. The unit of combined stress is kPa.

[0088] Step S3: Based on the load data, stress data, mid-span deflection of the beam, maximum combined stress, and displacement value, issue an early warning of the gantry crane's operating status.

[0089] Specifically, the step of providing an early warning of the gantry crane's operating status based on the load data, stress data, mid-span deflection of the beam, maximum combined stress, and displacement value includes:

[0090] When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective first thresholds, a first-level warning signal is issued for a first-level operational status warning; when the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective second thresholds, a second-level warning signal is issued for a second-level operational status warning; when the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective third thresholds, a third-level warning signal is issued for a third-level operational status warning; wherein the third threshold is greater than the second threshold, and the second threshold is greater than the first threshold.

[0091] Exemplary, such as Figure 7As shown, in this embodiment, a hierarchical early warning module connected to a cloud database is used to provide early warnings of the gantry crane's operating status. This early warning module can comprehensively determine the alarm based on the sensor data stored in the cloud database and the results calculated by the data calculation module, and then store the alarm information in the cloud database. In this embodiment, the gantry crane's operating status early warning is divided into three levels: Level 1 is a prompt warning, Level 2 is a warning, and Level 3 is an alarm. The specific details of the three levels are as follows:

[0092] When any one of the load value measured by the sensor, stress data, mid-span deflection of the beam, or maximum combined stress or displacement value calculated online exceeds the first threshold corresponding to the first-level operating status warning, a first-level warning signal is issued to remind monitoring personnel to pay attention and strengthen the observation of the structure.

[0093] When any one of the load value measured by the sensor, stress data, mid-span deflection of the beam, or maximum combined stress or displacement value calculated online exceeds the second threshold corresponding to the secondary operating state warning, a secondary warning signal is issued to remind monitoring and relevant personnel to take measures to adjust the structure, and construction continues.

[0094] When any of the load value measured by the sensor, stress data, mid-span deflection of the beam, or maximum combined stress or displacement value calculated online exceeds the third threshold corresponding to the level 3 operating status warning, a level 3 warning signal will be issued to remind that construction should be stopped immediately, emergency measures should be taken to prevent accidents, and relevant personnel should be asked to analyze the cause and further treat the structure before the next step of construction can be carried out.

[0095] In some embodiments, the conditions of the gantry crane's loading position being the mid-span of the beam, the gantry crane's rated lifting capacity being a first preset multiple, the gantry crane's self-weight load, a preset horizontal inertial load, and a preset wind load are applied to a pre-set gantry crane finite element model to obtain the stress data and the first threshold corresponding to the mid-span deflection of the beam, respectively; the conditions of the gantry crane's loading position being the mid-span of the beam, the gantry crane's rated lifting capacity being a second preset multiple, the gantry crane's self-weight load, and the preset horizontal inertial load are applied to a pre-set gantry crane finite element model to obtain the stress data and the first threshold corresponding to the mid-span deflection of the beam, respectively; The conditions of horizontal inertial load and preset wind load are applied to the preset gantry crane finite element model to obtain the second threshold corresponding to the stress data and the mid-span deflection of the crossbeam, respectively. The conditions of the gantry crane being loaded at the mid-span position of the crossbeam, the rated lifting capacity of the gantry crane being a third preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the third threshold corresponding to the stress data and the mid-span deflection of the crossbeam, respectively.

[0096] As an example, in this embodiment, the rated lifting capacity of the gantry crane is set to Gn. The determination of the threshold values ​​corresponding to the stress data of the gantry crane and the mid-span deflection of the crossbeam is mainly considered for static loads of 0.95Gn, 1.10Gn and 1.25Gn. The threshold values ​​of each parameter are obtained by substituting each parameter into the finite element model of the gantry crane for various working conditions.

[0097] Specifically, when calculating the stress data of the gantry crane and the first threshold corresponding to the mid-span deflection of the crossbeam, the trolley is moved to the mid-span position of the crossbeam, and the load combination is: self-weight load, threshold corresponding static load 0.95Gn (considering the impact coefficient), horizontal inertial load, and wind load are applied as conditions to the finite element model of the gantry crane for calculation.

[0098] When calculating the stress data of the gantry crane and the second threshold corresponding to the mid-span deflection of the crossbeam, the trolley is moved to the mid-span position of the crossbeam, and the load combination is: self-weight load, threshold corresponding static load 1.10Gn (considering the impact coefficient), horizontal inertial load, and wind load are applied as conditions to the finite element model of the gantry crane for calculation.

[0099] When calculating the stress data of the gantry crane and the third threshold corresponding to the mid-span deflection of the crossbeam, the trolley is moved to the mid-span position of the crossbeam, and the load combination is: self-weight load, threshold corresponding static load 1.25Gn (considering the impact coefficient), horizontal inertial load, and wind load are applied as conditions to the finite element model of the gantry crane for calculation.

[0100] Furthermore, after calculating and obtaining the first, second, and third threshold values ​​of the beam mid-span deflection corresponding to the beam mid-span deflection, the method further includes: determining whether the obtained third threshold value of the beam mid-span deflection corresponding to the beam mid-span deflection is greater than a preset beam mid-span deflection limit threshold. If so, then the beam mid-span deflection limit threshold, which is a fourth preset multiple, is used as the first threshold value of the beam mid-span deflection, the beam mid-span deflection limit threshold, which is a fifth preset multiple, is used as the second threshold value of the beam mid-span deflection, and the beam mid-span deflection limit threshold is used as the third threshold value of the beam mid-span deflection, wherein the fifth preset multiple is greater than the fourth preset threshold.

[0101] It is worth noting that, in addition to considering the static rigidity requirements of the crane, the calculation of the ultimate threshold for the mid-span deflection of the gantry crane beam also requires taking into account the mid-span deflection of the beam. The value of the ultimate threshold for the mid-span deflection of the beam is as follows:

[0102]

[0103] Where f is the mid-span deflection limit threshold of the crossbeam, S is the span of the gantry crane, and C is a constant parameter, which is determined based on the positioning accuracy of the gantry crane. For gantry cranes with low positioning accuracy requirements, or gantry cranes with stepless speed regulation control characteristics, and gantry cranes that can achieve acceptable positioning accuracy using low lifting speed and low acceleration, C is set to 500; for gantry cranes that can achieve medium positioning accuracy characteristics using a simple control system, C is set to 750; and for gantry cranes requiring high positioning accuracy characteristics, C is set to 1000. Therefore, the alarm threshold for the mid-span deflection of the gantry crane, i.e., the third threshold, should not exceed this value.

[0104] As an example, when the third threshold of the mid-span deflection of the beam is greater than the ultimate threshold of the mid-span deflection of the beam, then the first threshold of the mid-span deflection of the beam is 0.8f, the second threshold of the mid-span deflection of the beam is 0.9f, and the third threshold of the mid-span deflection of the beam is f.

[0105] As a preferred real-time method, when the first-level warning signal, the second-level warning signal, or the third-level warning signal is turned off, if the operating status warning level is increased, a warning signal of the corresponding level is issued; if the operating status warning level is the same or decreased, no more warning signals are issued, and the operating status warning information is stored.

[0106] As an example, once the warning threshold is determined, an alarm is triggered via Python programming when the measured parameters or online calculation results exceed a certain threshold level. The abnormal data is then stored in a cloud database using the pymysql sublibrary. Finally, the following alarm functions need to be implemented in Python: When alarm notifications are turned off, alarms of the same level will not be displayed for a period of time; only alarm information will continue to be stored. If the alarm level increases, the current alarm level notification will be displayed immediately. If notifications are turned off, alarms of the same or lower level will not be displayed for the same period of time, and so on.

[0107] Step S4: Generate a maximum combined stress cloud map based on the maximum combined stress, generate a gantry crane deformation cloud map based on the displacement value, display the maximum combined stress cloud map and the gantry crane deformation cloud map on the three-dimensional model of the gantry crane, and display the load data and the operating status warning information.

[0108] As an example, a visualization module generates and displays the maximum combined stress cloud map and the gantry crane deformation cloud map generated based on displacement values, along with load data. Specifically, the gantry crane model's .obj file is directly exported using Python programming. Combined with the maximum combined stress and displacement values ​​stored in the cloud database, and through backend data analysis and processing, the stress cloud map or deformation cloud map of the gantry crane's 3D model is displayed on a webpage, with color bars next to the cloud maps to display the corresponding color values. Secondly, based on the crane's position and lifting weight data in the database, the load status of the gantry crane is displayed on the webpage. Finally, based on alarm information in the database, the alarm location and alarm information are displayed on the webpage in real time.

[0109] It is worth noting that in this embodiment, the maximum combined stress cloud map is divided into 13 levels according to RGB colors. The closer the stressed part is to blue, the more severe the tension; the closer it is to red, the more severe the compression; and the closer it is to green, the less the stress. For the deformation cloud map of the gantry crane, the closer a part of the gantry crane is to blue, the greater the negative displacement of the node at that part; the closer it is to red, the greater the positive displacement of the node at that part; and the closer it is to green, the smaller the displacement. The sign of the displacement is determined according to the positive direction of the global coordinate axis.

[0110] In a preferred implementation, when the visualization module displays the operating status warnings of the gantry crane, it uses a green indicator to show the specific location and warning information when the warning for a certain part of the gantry crane is a Level 1 warning. When the warning for a certain part is a Level 2 warning, it uses an orange indicator to show the specific location and warning information. When the warning for a certain part is a Level 3 warning, it uses a red indicator to show the specific location and warning information.

[0111] It is worth noting that in this embodiment, the calculation of the maximum combined stress of the beam elements of the gantry crane and the displacement values ​​of the beam element nodes are performed periodically. The data calculation module determines whether there is an input command to terminate the calculation. If such a command is received, the calculation ends and the loop stops. If no such command is received, the load value and the loading position of the gantry crane are updated every 2 seconds based on the actual sensor data. The maximum combined stress of the beam elements of the gantry crane and the displacement values ​​of the beam element nodes are calculated based on the load value and the loading position, and the maximum combined stress cloud map and the gantry crane deformation cloud map are updated.

[0112] This embodiment provides a method for monitoring the operating status of a gantry crane. First, it can comprehensively obtain the actual load data, stress data, and mid-span deflection of the beam of the gantry crane through sensors. Based on the load data, it can calculate the deformation and stress values ​​at all locations on the gantry crane, no longer limited to measuring points. Therefore, whether the stress or deformation at measuring points or non-measuring points exceeds the threshold, this method can provide an early warning for the structural safety of the gantry crane, solving the problem of insufficient and incomplete stress measurement points for early warning. Furthermore, the sensor measurements at the measuring points can be combined with the calculated data results for comprehensive early warning judgment, reducing the possibility of false alarms or missed alarms due to sensor measurement deviations and improving the reliability of the early warning. Second, the real-time online data calculation module solves the serious disconnect between traditional health monitoring technology and mechanical calculation. Finally, through the status early warning module and real-time online visualization module, this invention can more intuitively display the current working status and stress deformation status of the gantry crane. Once an alarm occurs, the location of the risky stress structure is immediately apparent.

[0113] Secondly, embodiments of this application also provide a monitoring system for the operating status of a gantry crane, such as... Figure 3 As shown, the system includes:

[0114] The data acquisition module is used to acquire the load data, stress data, and mid-span deflection of the crossbeam of the gantry crane;

[0115] The data calculation module is used to determine the maximum combined stress of the beam unit of the gantry crane and the displacement value of the nodes of the beam unit based on the load data.

[0116] The status early warning module is used to provide early warning of the operating status of the gantry crane based on the load data, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, and the displacement value.

[0117] The visualization module is used to generate a maximum combined stress cloud map based on the maximum combined stress, generate a gantry crane deformation cloud map based on the displacement value, display the maximum combined stress cloud map and the gantry crane deformation cloud map on the 3D model of the gantry crane, and display the load data and the operating status warning information.

[0118] The system also includes:

[0119] A cloud-based database is used to store the load data, stress data, mid-span deflection of the beam, maximum combined stress of the beam element, and displacement values ​​of the nodes of the beam element.

[0120] The data acquisition module further includes:

[0121] A side-pressure tension sensor is installed on the hook of the gantry crane to monitor the load value of the gantry crane;

[0122] An optical encoder is installed on the overhead crane of the gantry crane to monitor the load position of the gantry crane;

[0123] Surface strain gauges are respectively installed at the mid-span of the crossbeam and the middle of the outrigger of the gantry crane to monitor the stress data;

[0124] A static level is installed at the leftmost end and the middle of the crossbeam of the gantry crane to monitor the deflection at the middle of the crossbeam.

[0125] The data calculation module is further used for:

[0126] The load and boundary conditions are applied to the pre-set finite element model of the gantry crane according to the load value and the load position;

[0127] The internal forces of the beam element and the displacement values ​​of the nodes of the beam element are obtained by calculating using the finite element model of the gantry crane.

[0128] The maximum combined stress of the beam element is obtained by calculating the internal forces of the beam element.

[0129] The internal forces of the beam element include axial force, bending moment, and shear force.

[0130] The status warning module is also used for:

[0131] When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective first threshold, a first-level early warning signal is issued to provide a first-level operational status warning.

[0132] When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective second thresholds, a level-two warning signal is issued to provide a level-two operational status warning.

[0133] When the load value, stress data, mid-span deflection of the crossbeam, maximum combined stress, or displacement value of the gantry crane exceed their respective third threshold, a level three warning signal is issued to provide a level three operational status warning.

[0134] The third threshold is greater than the second threshold, and the second threshold is greater than the first threshold.

[0135] The status warning module is also used for:

[0136] When the first-level warning signal, the second-level warning signal, or the third-level warning signal is turned off, if the operating status warning level is increased, a warning signal of the corresponding level will be issued. If the operating status warning level is the same or decreased, no more warning signals will be issued, and the operating status warning information will be stored.

[0137] The status warning module is also used for:

[0138] The conditions of loading the gantry crane at the mid-span of the beam, the rated lifting capacity of the gantry crane by a first preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the first threshold corresponding to the stress data and the mid-span deflection of the beam, respectively.

[0139] The conditions of loading the gantry crane at the mid-span of the crossbeam, the rated lifting capacity of the gantry crane by a second preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the second threshold corresponding to the stress data and the mid-span deflection of the crossbeam.

[0140] The loading conditions of the gantry crane being at the mid-span of the crossbeam, the rated lifting capacity of the gantry crane being a third preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the stress data and the third threshold corresponding to the mid-span deflection of the crossbeam.

[0141] The status warning module is also used for:

[0142] Determine whether the third threshold of the mid-span deflection of the beam corresponding to the obtained mid-span deflection is greater than the preset limit threshold of the mid-span deflection of the beam;

[0143] If so, the fourth preset multiple of the beam mid-span deflection limit threshold is taken as the first threshold of beam mid-span deflection, the fifth preset multiple of the beam mid-span deflection limit threshold is taken as the second threshold of beam mid-span deflection, and the beam mid-span deflection limit threshold is taken as the third threshold of beam mid-span deflection, wherein the fifth preset multiple is greater than the fourth preset multiple.

[0144] The value of the mid-span deflection limit threshold of the crossbeam is:

[0145]

[0146] Where f is the mid-span deflection limit threshold of the beam, S is the span of the gantry crane, and C is a constant parameter, which is determined according to the positioning accuracy of the gantry crane.

[0147] It should be noted that those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the above-described device and its modules and units can be referred to the corresponding processes in the foregoing embodiments, and will not be repeated here.

[0148] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0149] The sequence numbers of the embodiments in this application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments. The above descriptions are merely specific implementations of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for monitoring the operating status of a gantry crane, characterized in that, include: Obtain the load data, stress data, and mid-span deflection of the crossbeam of the gantry crane; The maximum combined stress of the beam element of the gantry crane and the displacement value of the nodes of the beam element are determined based on the load data. The gantry crane's operating status is warned based on the load data, stress data, mid-span deflection of the crossbeam, maximum combined stress, and displacement value. A maximum combined stress cloud map is generated based on the maximum combined stress, and a gantry crane deformation cloud map is generated based on the displacement value. The maximum combined stress cloud map and the gantry crane deformation cloud map are displayed on the three-dimensional model of the gantry crane, along with the load data and the operating status warning information. The acquisition of the gantry crane's load data, stress data, and mid-span deflection of the crossbeam includes: The load value of the gantry crane is monitored by a side pressure tension sensor installed on the hook of the gantry crane, and the load position of the gantry crane is monitored by a photoelectric encoder installed on the overhead crane. The stress data were monitored by surface strain gauges installed at the mid-span of the beam and the middle of the outriggers of the gantry crane, respectively. The deflection at the mid-span of the beam was monitored by static level instruments set at the leftmost end and the mid-span of the beam of the gantry crane, respectively. The step of determining the maximum combined stress of the beam element of the gantry crane and the displacement values ​​of the nodes of the beam element based on the load data includes: The load and boundary conditions are applied to the pre-set finite element model of the gantry crane according to the load value and the load position; The internal forces of the beam element and the displacement values ​​of the nodes of the beam element are obtained by calculating using the finite element model of the gantry crane. The maximum combined stress of the beam element is obtained by calculating the internal forces of the beam element. The internal forces of the beam element include axial force, bending moment, and shear force.

2. The method for monitoring the operating status of a gantry crane according to claim 1, characterized in that, The method of providing an early warning of the gantry crane's operating status based on the load data, stress data, mid-span deflection of the beam, maximum combined stress, and displacement value includes: When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective first threshold, a first-level early warning signal is issued to provide a first-level operational status warning. When the load value of the gantry crane, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, or the displacement value exceeds their respective second thresholds, a level-two warning signal is issued to provide a level-two operational status warning. When the load value, stress data, mid-span deflection of the crossbeam, maximum combined stress, or displacement value of the gantry crane exceed their respective third threshold, a level three warning signal is issued to provide a level three operational status warning. The third threshold is greater than the second threshold, and the second threshold is greater than the first threshold.

3. The method for monitoring the operating status of a gantry crane according to claim 2, characterized in that, Also includes: When the Level 1 warning signal, Level 2 warning signal, or Level 3 warning signal is turned off, if the operating status warning level is increased, a warning signal of the corresponding level will be issued. If the operating status warning level is the same or decreased, no more warning signals will be issued, and the operating status warning information will be stored.

4. The method for monitoring the operating status of a gantry crane according to claim 2, characterized in that, Also includes: The conditions of loading the gantry crane at the mid-span of the beam, the rated lifting capacity of the gantry crane by a first preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the first threshold corresponding to the stress data and the mid-span deflection of the beam, respectively. The conditions of loading the gantry crane at the mid-span of the crossbeam, the rated lifting capacity of the gantry crane by a second preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the second threshold corresponding to the stress data and the mid-span deflection of the crossbeam. The loading conditions of the gantry crane being at the mid-span of the crossbeam, the rated lifting capacity of the gantry crane being a third preset multiple, the self-weight load of the gantry crane, the preset horizontal inertial load, and the preset wind load are applied to the preset gantry crane finite element model to obtain the stress data and the third threshold corresponding to the mid-span deflection of the crossbeam.

5. The method for monitoring the operating status of a gantry crane according to claim 4, characterized in that, Also includes: Determine whether the third threshold of the mid-span deflection of the beam corresponding to the obtained mid-span deflection is greater than the preset limit threshold of the mid-span deflection of the beam; If so, the fourth preset multiple of the beam mid-span deflection limit threshold is taken as the first threshold of beam mid-span deflection, the fifth preset multiple of the beam mid-span deflection limit threshold is taken as the second threshold of beam mid-span deflection, and the beam mid-span deflection limit threshold is taken as the third threshold of beam mid-span deflection, wherein the fifth preset multiple is greater than the fourth preset multiple. The value of the mid-span deflection limit threshold of the crossbeam is: in, f The mid-span deflection limit threshold of the beam is... S For the span of the gantry crane, C These are constant parameters, and their values ​​are determined based on the positioning accuracy of the gantry crane.

6. A monitoring system for the operating status of a gantry crane, characterized in that, include: The data acquisition module is used to acquire the load data, stress data, and mid-span deflection of the crossbeam of the gantry crane; The data calculation module is used to determine the maximum combined stress of the beam unit of the gantry crane and the displacement value of the nodes of the beam unit based on the load data. The status early warning module is used to provide early warning of the operating status of the gantry crane based on the load data, the stress data, the mid-span deflection of the crossbeam, the maximum combined stress, and the displacement value. The visualization module is used to generate a maximum combined stress cloud map based on the maximum combined stress, generate a gantry crane deformation cloud map based on the displacement value, display the maximum combined stress cloud map and the gantry crane deformation cloud map on the three-dimensional model of the gantry crane, and display the load data and the operating status warning information. The data acquisition module includes: A side-pressure tension sensor is installed on the hook of the gantry crane to monitor the load value of the gantry crane; An optical encoder is installed on the overhead crane of the gantry crane to monitor the load position of the gantry crane; Surface strain gauges are respectively installed at the mid-span of the crossbeam and the middle of the outrigger of the gantry crane to monitor the stress data; A static level is installed at the leftmost end and the middle of the crossbeam of the gantry crane to monitor the deflection at the middle of the crossbeam. The data calculation module is further used for: The load and boundary conditions are applied to the pre-set finite element model of the gantry crane according to the load value and the load position; The internal forces of the beam element and the displacement values ​​of the nodes of the beam element are obtained by calculating using the finite element model of the gantry crane. The maximum combined stress of the beam element is obtained by calculating the internal forces of the beam element. The internal forces of the beam element include axial force, bending moment, and shear force.

7. The monitoring system for the operating status of a gantry crane according to claim 6, characterized in that, The system also includes: A cloud-based database is used to store the load data, stress data, mid-span deflection of the beam, maximum combined stress of the beam element, and displacement values ​​of the nodes of the beam element.

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