Micro-motion unbalance loading detection control system for balance beam of crane

Abstract

The invention discloses a jogging and unbalance loading detection control system for a balance beam of a crane. The system comprises a fixed pulley block, a weighing sensor, a collector, a data processor and an unbalance loading limiter, wherein the fixed pulley block is installed on a crane trolley frame, the weighing sensors are installed on the two sides of the shaft end of the fixed pulley block, the weighing sensors are connected with the collector, the collector is connected with the data processor, and the data processor is connected with the unbalance load limiter. The weighing metering and safety control functions are integrated, installation and debugging are easy, implementation is easy, and an effective low-cost solution is provided for accurate weighing metering of the crane and safety management of crane equipment.

Description

Technical Field

[0001] The invention relates to the technical field of crane safety control, and in particular to a crane balance beam micro-motion eccentric load detection and control system. Background Art

[0002] The crane balance beam plays a vital role in lifting operations. Its core functions include: effectively maintaining the balance of the hoisted equipment to prevent damage to the equipment or the sling due to the horizontal force generated by tilted lifting; shortening the height of the sling, thereby reducing the lifting height of the movable pulley, and improving the efficiency and safety of the lifting operation; during the equipment lifting process, it can reduce the horizontal pressure on the equipment, thereby avoiding equipment damage caused by excessive pressure; in the case of multiple machines lifting, it can reasonably distribute or balance the load of each lifting point to ensure the safety and efficiency of the lifting operation.

[0003] The existing technology is to detect the rotation angle of the crane balance beam. When it exceeds the preset angle, the limiter can stop the lifting movement. Depending on the installation position of the fixed frame on which the balance beam relies, the technical solutions are different, as follows:

[0004] First, the fixed frame is installed on the crane trolley frame, and an angle sensor installed on the crane balance beam can be used as a detection unit to detect the rotation angle of the balance beam. When the preset angle is reached, the limiter stops the lifting movement.

[0005] Second, the fixed frame is installed on the crane trolley frame, and a proximity switch can also be installed on the crane trolley frame as a detection unit to detect the rotation angle of the balance beam. When the balance beam rotates to a preset angle, the proximity switch is triggered and the limiter stops the lifting movement.

[0006] Third, the fixed frame is installed on the crane sling, and a laser rangefinder can be installed on the trolley frame and the wire rope connection of the balance beam as a detection unit to detect the rotation angle of the balance beam. When the preset angle is reached, the limiter stops the lifting movement.

[0007] Although the above-mentioned prior art meets the special requirement that the compensation device of the winding system of the metallurgical bridge crane for lifting molten metal should be equipped with a limiter, it has some technical disadvantages, as follows: First, the installation and debugging are difficult. Because it is necessary to accurately install detection units such as angle sensors, proximity switches, laser rangefinders or wire encoders on the trolley frame, and the preset rotation angle of the balance beam of cranes with different structures and different tonnages is difficult to know in advance, and it needs to be determined according to the actual working conditions of the specific crane, which brings difficulties to the installation and debugging of the detection unit; second, power supply and signal transmission are inconvenient. For the case where the fixed frame is installed on the crane hoist, if the detection unit signal transmission is wireless, it is necessary to configure a wireless data transmission module and use a battery for power supply. In this case, the battery needs to be replaced frequently, increasing the maintenance workload; if the detection unit signal transmission is wired, it is necessary to set a cable reel on the trolley frame, and the signal cable wound by the cable reel is used to power the detection unit installed on the crane hoist. The signal cable layout must be It must be reasonable to avoid interference and entanglement with the cable during the lifting of the hoist; third, the working environment of the detection unit is harsh and the reliability is poor. When the fixed frame is installed on the crane hoist, the hoist lifts high-temperature molten metal, and the installation position of the detection unit is in a high-temperature environment, with large vibration and shock, and a harsh working environment, which will seriously affect the reliability of the detection unit; Fourth, the performance is poor. The limiter will stop the lifting movement only when the detection unit detects that the balance beam has rotated more than the preset angle; if hidden dangers such as mechanical failure of the fixed frame and abnormality of the wire rope have already occurred, which may lead to danger, the detection unit cannot issue a hidden danger risk warning in advance when it detects that the rotation of the balance beam has not exceeded the preset angle; Fifth, the cost is high, because additional detection units are required, and the working environment of the detection unit is harsh, resulting in high use and maintenance costs. Summary of the invention

[0008] The purpose of the present invention is to provide a crane balance beam micro-motion eccentric load detection and control system, which integrates and combines weighing and safety control functions, is easy to install and debug, and easy to implement, and provides an effective and low-cost solution for accurate crane weighing and crane equipment safety management.

[0009] To achieve the above object, the present invention provides the following solutions:

[0010] A crane balance beam micro-motion eccentric load detection and control system includes a fixed pulley block, a weighing sensor, a collector, a data processor, and an eccentric load limiter; wherein:

[0011] The fixed pulley block is installed on the crane trolley frame, the weighing sensor is installed on both sides of the shaft end of the fixed pulley block, the weighing sensor is connected to the collector, the collector is connected to the data processor, and the data processor is connected to the eccentric load limiter.

[0012] Preferably, the fixed pulley block is installed on the crane trolley frame, and a double fixed pulley block and double balance beam structure is adopted, and each fixed pulley block corresponds to a balance beam.

[0013] Preferably, there are multiple weighing sensors, which are respectively installed on both sides of the shaft end of the fixed pulley block, and are used to sense and measure the weight of the hoisted materials and the micro-force on both sides of the balance beam.

[0014] Preferably, the collector adopts a multimodal collector with multiple mutually isolated independent AD acquisition channels, which are respectively connected to the weighing sensors, and the analog signal of the load sensed by each weighing sensor is collected in real time and digitally converted to generate code values, and the code values ​​are output through serial port communication.

[0015] Preferably, the data processor adopts a weighing meter or an industrial touch screen, receives the code value corresponding to the load sensed by the weighing sensor in the data transmitted by the collector, and then displays and outputs it after calculation and preprocessing.

[0016] Preferably, the collector and the data processor communicate with each other by cable connection or WIFI wireless transmission.

[0017] Preferably, the eccentric load limiter communicates with the data processor to transmit the code value data corresponding to the load sensed by the weighing sensor, and then groups the data according to the corresponding balance beams, and then compares, calculates, displays and outputs the grouped data for control.

[0018] Preferably, the unbalanced load limiter includes a relay output control circuit for sound and light early warning and alarm output control of unbalanced load, underload and overload, and automatically generates alarm record storage.

[0019] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0020] (1) The crane balance beam micro-motion eccentric load detection and control system of the present invention directly utilizes the weighing sensor configured by the existing crane electronic scale as the detection unit, integrating and fusing the weighing and safety control functions into one, which is easy to install and debug, and easy to implement, and provides an effective and low-cost solution for accurate crane weighing and safety management of crane equipment.

[0021] (2) The micro-motion overload detection and control system of the crane balance beam of the present invention detects whether the forces on both sides of the balance beam are balanced, and judges whether there is overload based on this. By adding an overload limiter, it can realize early sound and light warning and stop lifting motion control for potential accidents caused by unbalanced forces due to mechanical failure of the fixed frame and abnormality of the wire rope winding system (such as the lifting of the wire rope is not strictly synchronized, mechanical jamming, wire rope breakage and cracking failure, etc.). It helps to timely discover and eliminate possible safety hazards, prevent various accidents, and safeguard safe production.

[0022] (3) The crane balance beam micro-motion eccentric load detection and control system of the present invention has many advantages such as advanced technical performance, high degree of automation, convenient installation and maintenance, strong practicality, safety and reliability, and has significant economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0024] Figure 1 A structural diagram of a crane balance beam micro-motion eccentric load detection and control system provided by the present invention;

[0025] Among them, 1-fixed pulley block, 2-weighing sensor, 3-collector, 4-data processor, 5-eccentric load limiter;

[0026] Figure 2 This is a principle block diagram of Embodiment 1 of the present invention;

[0027] Figure 3 This is a principle block diagram of Embodiment 2 of the present invention;

[0028] Figure 4 This is the main screen of the data processing machine in the embodiment of the present invention;

[0029] Figure 5 This is the main screen 1 of the eccentric load limiter according to the embodiment of the present invention;

[0030] Figure 6 This is the main screen 2 of the eccentric load limiter according to an embodiment of the present invention. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] Reference Figure 1 As shown, the present invention discloses a crane balance beam micro-motion eccentric load detection and control system, comprising a fixed pulley block 1, a weighing sensor 2, a collector 3, a data processor 4, and an eccentric load limiter 5; wherein,

[0033] The fixed pulley block 1 is installed on the crane trolley frame, the weighing sensor 2 is installed on both sides of the shaft end of the fixed pulley block, the weighing sensor 2 is connected to the collector 3, the collector 3 is connected to the data processor 4, and the data processor 4 is connected to the eccentric load limiter 5.

[0034] Furthermore, the fixed pulley block 1 is installed on the crane trolley frame. Depending on the structure and tonnage of the crane, there are two fixed pulley blocks and two balance beams, each fixed pulley block corresponds to a balance beam; there are also four pulley blocks and two balance beams, each two fixed pulley blocks correspond to a balance beam.

[0035] Furthermore, there are multiple weighing sensors 2, which are respectively installed on both sides of the shaft end of the fixed pulley group 1 to sense and measure the weight of the hoisted materials and the micro-force on both sides of the balance beam; for the use of double fixed pulley groups and double balance beams, four weighing sensors are configured; for the use of four fixed pulley groups and double balance beams, eight weighing sensors are configured.

[0036] Furthermore, the collector 3 adopts a multi-modal collector, which has multiple isolated and independent AD acquisition channels, which are respectively connected to the weighing sensor 2, and the analog signal of each weighing sensor 2 sensing the load is collected in real time and converted digitally to generate a code value, which is output through the serial port communication. Its acquisition circuit can collect and process the on-site working temperature, battery power, drum rotation speed, sling lifting height and the load of each connected weighing sensor. Its acquisition circuit can also sense whether the wiring of each weighing sensor is abnormal and generate event information. The collector 3 has the functions of self-test, fault diagnosis, detection data and event information output, which is convenient for on-site monitoring and remote operation and maintenance.

[0037] Furthermore, the data processor 4 uses a weighing meter, an industrial touch screen or a computer to receive the code value corresponding to the load sensed by the weighing sensor in the data transmitted by the collector, and then displays and outputs it after calculation and preprocessing.

[0038] Specifically, when the data processor 4 is designed as a weighing meter, in addition to realizing the basic functions of the crane electronic scale, the code value corresponding to the load sensed by each weighing sensor is pre-processed and transmitted to the overload limiter; the data processor 4 can also use an industrial touch screen or a computer, which can not only complete the functions of the above-mentioned weighing meter, but also generate weighing records, weighing reports and data curves.

[0039] Furthermore, the collector 3 and the data processor 4 communicate with each other by cable connection or WIFI wireless transmission.

[0040] Furthermore, the eccentric load limiter 5 communicates with the data processor 4 to transmit the code value data corresponding to the load sensed by the load sensor, and then groups the data according to the corresponding balance beams, and then compares, calculates, displays and outputs the grouped data for control.

[0041] Specifically, the data processor 3 and the eccentric load limiter 5 may exist separately or may be integrated into one.

[0042] Furthermore, the unbalanced load limiter 5 includes a relay output control circuit for sound and light warning and alarm output control of unbalanced load, underload and overload, and automatically generates alarm record storage.

[0043] In specific embodiment 1, Figure 2 As shown, the implementation method of the double fixed pulley group double balance beam structure is adopted:

[0044] A crane balance beam micro-motion eccentric load detection and control system comprises a fixed pulley block 1, a weighing sensor 2, a collector 3, a data processor 4, and an eccentric load limiter 5; the fixed pulley block 1 is installed on a crane trolley frame, the weighing sensor 2 is installed on both sides of the shaft end of the fixed pulley block 1, the weighing sensor 2 is connected to the collector 3 through a cable, the collector 3 is connected to the data processor 4 through a cable, and the data processor 4 is connected to the eccentric load limiter 5 through a cable.

[0045] Among them, the fixed pulley block 1 is installed on the crane trolley frame, and adopts a double fixed pulley block and double balance beam structure. The fixed pulley block I corresponds to the balance beam A, and the fixed pulley block II corresponds to the balance beam B.

[0046] Among them, there are four weighing sensors 2, which are respectively installed on both sides of the shaft end of the fixed pulley block 1, and sense the weight of the hoisted materials and the micro-force on both sides of the balance beam; weighing sensor ① detects the force on the left side of the balance beam A, weighing sensor ② detects the force on the right side of the balance beam A, weighing sensor ③ detects the force on the left side of the balance beam B, and weighing sensor ④ detects the force on the right side of the balance beam B.

[0047] Among them, the collector 3 is designed as a multimodal collector, having four mutually isolated and independent 32-bit AD acquisition channels X1~X4, which are respectively connected to the weighing sensors, and the analog signal of the load sensed by each weighing sensor is collected in real time and digitally converted to generate a code value, which is output through serial port communication; weighing sensor ① is connected to the X1 channel of the collector, weighing sensor ② is connected to the X2 channel of the collector, weighing sensor ③ is connected to the X3 channel of the collector, and weighing sensor ④ is connected to the X4 channel of the collector.

[0048] The acquisition circuit designed by the multi-mode collector can also collect and process the on-site working temperature, battery power, drum rotation speed, and hoisting height of the hoist; the four weighing sensor acquisition circuits designed by the multi-mode collector can automatically identify whether the weighing sensor is open, short, connected in reverse, or connected incorrectly, and realize online alarms and generate event alarm information through indicator lights of different colors; the multi-mode collector has multiple RS485 bidirectional isolated high-speed communication interface circuits, which can package the weighing sensor load code value data, on-site working temperature data, battery power data, drum rotation speed data, hoisting height data, and event alarm information collected by the X1~X4 acquisition channels and output them through RS485 communication; the multi-mode collector has self-test, fault diagnosis, detection data and event information output functions, which are convenient for on-site monitoring and remote operation and maintenance.

[0049] Among them, the data processor 4 adopts an industrial touch screen with TFT true color Chinese display. Figure 4 As shown, it is an industrial multifunctional digital weighing control system used for crane weighing measurement control and weighing data management. It receives all the data transmitted by the collector to first complete the crane electronic scale weighing measurement function, and can also realize the automatic generation of weighing records, weighing scales, weighing reports, and data curves; the data processor also outputs the code value corresponding to the load sensed by the weighing sensor through the Ethernet port and serial port communication.

[0050] Among them, the eccentric load limiter 5 can be used as an industrial touch screen. Figure 5 As shown, the weighing sensor 2 senses the code value data corresponding to the load transmitted by the communication access data processor 4, and then groups them according to the corresponding balance beams, and then performs group data comparison operations, reasoning, display and output control.

[0051] The code values ​​of the load sensed by the four load cells received by the eccentric load limiter 5 are X1 to X4, which correspond to the forces on the two balance beams: the force on the left side of the balance beam A is X1, and the force on the right side of the balance beam A is X2.

[0052] The force on the left side of balance beam B is X3, and the force on the right side of balance beam B is X4.

[0053] For the balance beam A, by comparing and calculating the difference between X1 and X2, when the difference (X1-X2) is very small and belongs to the normal range, the balance beam A is deemed to have no overload; when the difference (X1-X2) is larger and exceeds the normal range and reaches the warning value, it is deemed that the balance beam A is overloaded, and the overload limiter 5 shows left or right deviation, and sends out an audible and visual warning signal, prompting the crane operator or maintenance personnel to take timely measures to eliminate hidden dangers; when the difference (X1-X2) greatly exceeds the warning value and reaches the alarm value, it is deemed that the balance beam A is seriously overloaded, and the overload limiter 5 shows left or right deviation, and while sending out the audible and visual alarm signal, the control point is immediately output to cut off the power supply of the lifting circuit to stop the lifting mechanism.

[0054] For the balance beam B, by comparing and calculating the difference between X3 and X4, when the difference (X3-X4) is very small and belongs to the normal range, it is regarded that the balance beam B has no overload; when the difference (X3-X4) is larger and exceeds the normal range and reaches the warning value, it is regarded that the balance beam B is overloaded, and the overload limiter 5 shows left or right deviation, and sends out an audible and visual warning signal, prompting the crane operator or maintenance personnel to take timely measures to eliminate hidden dangers; when the difference (X3-X4) greatly exceeds the warning value and reaches the alarm value, it is regarded that the balance beam B is seriously overloaded, and the overload limiter 5 shows left or right deviation, and while sending out the audible and visual alarm signal, the control point is immediately output to cut off the power supply of the lifting circuit to stop the lifting mechanism.

[0055] Among them, the eccentric load limiter 5 can also be used as an industrial touch screen. Figure 6 As shown, the weighing sensor 2 senses the code value data corresponding to the load transmitted by the communication access data processor 4, and then groups them according to the corresponding balance beams, and then performs group data comparison operations, reasoning, display and output control.

[0056] The eccentric load limiter 5 receives the code values ​​of the loads sensed by four weighing sensors, which are X1~X4 respectively, and the corresponding relationship with the forces on the two balance beams is: the force on the left side of balance beam A is X1, and the force on the right side of balance beam A is X2; the force on the left side of balance beam B is X3, and the force on the right side of balance beam B is X4.

[0057] For balance beam A, calculate the sum of X1 and X2, (X1+X2)=A is the total load code value of balance beam A, corresponding to the force on the left side of the entire crane sling; for balance beam B, calculate the sum of X3 and X4, (X3+X4)=B is the total load code value of balance beam B, corresponding to the force on the right side of the entire crane sling.

[0058] For the entire crane sling, by comparing and calculating the difference between A and B, when the (AB) difference is very small and within the normal range, it is considered that the sling is not overloaded; when the (AB) difference is very large and exceeds the normal range to reach the warning value, it is considered that the sling is overloaded, and the overload limiter 5 shows left or right deviation, and sends out an audible and visual warning signal to prompt the crane operator or maintenance personnel to take timely measures to check for hidden dangers; when the (AB) difference greatly exceeds the warning value and reaches the alarm value, it is considered that the sling is seriously overloaded, and the overload limiter 5 shows left or right deviation, and immediately outputs the control point to cut off the power supply of the lifting circuit to stop the lifting mechanism while sending out the audible and visual alarm signal. The overload limiter 5 is designed with a relay output control circuit, which can also realize the audible and visual warning and alarm output control of underload and overload by monitoring the real-time weight data of the crane hoisting materials.

[0059] The eccentric load limiter 5 can automatically generate an alarm record and store it for future reference.

[0060] In specific embodiment 2, Figure 3 As shown, the implementation method of the four-fixed pulley group double balance beam structure is adopted:

[0061] This embodiment is different from the first embodiment only in the corresponding relationship between the fixed pulley block, the weighing sensor and the balance beam, and the rest is consistent with the first embodiment.

[0062] Specifically, the fixed pulley block 1 is installed on the crane trolley frame, and adopts a four-fixed pulley block and a double balance beam structure. The fixed pulley block I and the fixed pulley block II correspond to the balance beam A, and the fixed pulley block III and the fixed pulley block IV correspond to the balance beam B.

[0063] Specifically, there are eight weighing sensors 2, which are respectively installed on both sides of the shaft end of the fixed pulley group 1, and sense the weight of the hoisted materials and the micro-force on both sides of the balance beam; weighing sensor ① and weighing sensor ② are installed in parallel on both sides of the shaft end of the fixed pulley group I, corresponding to the force on the left side of the balance beam A, weighing sensor ③ and weighing sensor ④ are installed in parallel on both sides of the shaft end of the fixed pulley group II, corresponding to the force on the right side of the balance beam A; weighing sensor ⑤ and weighing sensor ⑥ are installed in parallel on both sides of the shaft end of the fixed pulley group III, corresponding to the force on the left side of the balance beam B, and weighing sensor ⑦ and weighing sensor ⑧ are installed in parallel on both sides of the shaft end of the fixed pulley group IV, corresponding to the force on the right side of the balance beam B.

[0064] Through the description of the above implementation methods, those skilled in the art can clearly understand that each implementation method can be implemented by means of software plus a necessary general hardware platform, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solution is essentially or the part that contributes to the prior art can be embodied in the form of a software product, and the computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, a disk, an optical disk, etc., including a number of instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in each embodiment or some parts of the embodiments.

[0065] The principles and implementation methods of the present invention are described in this article using specific examples. The description of the above embodiments is only used to help understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, according to the idea of ​​the present invention, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A crane balance beam micro-motion eccentric load detection and control system, It is characterized in that It includes a fixed pulley block, a weighing sensor, a collector, a data processor, and an eccentric load limiter; wherein, The fixed pulley block is installed on the crane trolley frame, the weighing sensor is installed on both sides of the shaft end of the fixed pulley block, the weighing sensor is connected to the collector, the collector is connected to the data processor, and the data processor is connected to the eccentric load limiter.

2. A crane balance beam micro-motion eccentric load detection and control system according to claim 1, It is characterized in that The fixed pulley block is installed on the crane trolley frame and adopts a double fixed pulley block and double balance beam structure, and each fixed pulley block corresponds to a balance beam.

3. A crane balance beam micro-motion eccentric load detection and control system according to claim 2, It is characterized in that There are multiple weighing sensors, which are respectively installed on both sides of the shaft end of the fixed pulley group, and are used to sense and measure the weight of the hoisted materials and the micro-force on both sides of the balance beam.

4. A crane balance beam micro-motion eccentric load detection and control system according to claim 3, It is characterized in that The collector adopts a multimodal collector with multiple mutually isolated independent AD acquisition channels, which are respectively connected to the weighing sensors, and the analog signal of each weighing sensor sensing the load is collected in real time and digitally converted to generate code values, which are output through serial port communication.

5. A crane balance beam micro-motion eccentric load detection and control system according to claim 4, It is characterized in that The data processor adopts a weighing meter or an industrial touch screen to receive the code value corresponding to the load sensed by the weighing sensor in the data transmitted by the collector, and then displays and outputs it after calculation and preprocessing.

6. A crane balance beam micro-motion eccentric load detection and control system according to claim 5, It is characterized in that The collector and the data processor communicate with each other by cable connection, wired transmission or WIFI wireless transmission.

7. A crane balance beam micro-motion eccentric load detection and control system according to claim 6, It is characterized in that The eccentric load limiter communicates with the code value data corresponding to the load sensed by the weighing sensor transmitted by the data processor, and then groups the data according to the corresponding balance beams, and then compares, calculates, infers, displays and outputs the grouped data.

8. A crane balance beam micro-motion eccentric load detection and control system according to claim 7, It is characterized in that The unbalanced load limiter comprises a relay output control circuit, which is used for sound and light early warning and alarm output control of unbalanced load, underload and overload, and automatically generates alarm record storage.

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