A risk warning method and system for crane hoisting operation process

Abstract

The present invention provides a method and system for early warning of risks in the process of crane hoisting operations, and relates to the technical field of early warning of risks in crane hoisting operations. The present invention obtains actual data through pre-operation tests, corrects the load in combination with wind speed, load matrix and dynamic factors, and generates a fitting equation to predict future load conditions. Dynamic monitoring and accurate evaluation of the load on the crane boom are achieved, significantly improving the accuracy of risk management. Compared with traditional methods, this solution can predict the operating conditions in advance and conduct risk assessment, thereby preventing potential accidents and providing reliable safety protection for operators. This not only improves the safety of crane operations, but also optimizes equipment management and maintenance processes, providing an effective solution for high-risk operation scenarios.

Description

Technical Field

[0001] The present invention relates to the technical field of crane hoisting risk warning, and in particular to a crane hoisting operation process risk warning method and system. Background Art

[0002] In crane hoisting operations, the dynamic load problem of the boom is a long-standing challenge. Traditional methods rely on static calculations and empirical speculation, lacking real-time monitoring and analysis of dynamic working conditions, resulting in inaccurate risk assessment. During the operation of the crane, the dynamic load will be affected by multiple factors such as vibration, wind force, and equipment aging. These factors will generate unpredictable risks during the operation, which may lead to equipment damage or safety accidents.

[0003] For example, a safety risk monitoring method and system for crane operation scenarios published by Chinese patent publication number CN118365143A includes: obtaining environmental parameter information and load item parameter information; obtaining environmental parameter thresholds and load parameter thresholds; obtaining environmental threshold ranges and load threshold ranges; performing influence analysis on crane components and matching safety risk events; configuring pre-detection parameters and tracking monitoring parameters, performing pre-operation risk detection and prediction evaluation on the crane according to the pre-detection parameters, monitoring the crane during the operation according to the tracking monitoring parameters, and performing risk prediction based on the risk monitoring information in the operation and the pre-operation risk detection information; based on the risk monitoring information in the operation and the risk prediction results, adaptive control is performed according to the adaptive list. Although this scheme can be based on the collection and analysis of real-time working condition data, it still belongs to the scope of passive monitoring. When the risk is detected, the risk event has already occurred, which makes it difficult to reflect the overall risk situation of the operation, which is not conducive to prediction in high-risk scenarios and has low applicability. Therefore, there is an urgent need for a system that can actively analyze working condition data and evaluate and warn the overall risk situation of the operation to improve the guarantee of the safety of hoisting operations.

[0004] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not constitute the prior art that is already known to one of ordinary skill in the art. Summary of the invention

[0005] The purpose of the present invention is to provide a method and system for early warning of risks in a crane hoisting operation process, so as to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A risk early warning method for a crane hoisting operation process, the specific steps comprising:

[0008] S1: Conduct a pre-operation test based on the crane to be warned, and collect the total load of the key parts of the crane boom and the wind speed of the environment where the key parts of the crane boom are located during the pre-operation test;

[0009] S2: According to the wind speed of the environment where the key parts of the crane boom are located, the total load of the key parts is corrected, the load matrix is ​​constructed according to the corrected total load, and the curve fitting is performed according to the load matrix to generate the corresponding fitting equation;

[0010] S3: Collect the working condition data of the crane during actual operation, generate the load safety factor based on the working condition data and the fitting equation, judge the risk level of the lifting operation according to the load safety factor, and generate the corresponding risk warning.

[0011] Preferably, each time the pre-operation test is performed, the same load to be lifted is lifted at a uniform speed at the same lifting speed, and the pre-operation test is repeated at least three times, and in each pre-operation test, the lifting speed is repeated at the same time interval. At the same time, the total load of the key parts of the crane boom and the wind speed in the environment where the crane is located are collected.

[0012] Preferably, the logic for correcting the total load of key parts according to the wind speed of the environment in which the crane is located is:

[0013] The wind load is calculated based on the wind speed in the environment where the key parts of the crane boom are located. The calculation method is:

[0014] ;

[0015] In the formula Indicates the crane boom The key part is The wind speed at the time of the first collection, Indicates the crane boom The key part is The wind load corresponding to the wind speed at the time of the first collection is Indicates the crane boom The windward area of ​​the key parts, represents the air density, Indicates the preset drag coefficient, The index indicating the number of collections. Indicates the index of the key parts of the crane boom;

[0016] Then calculate the theoretical load of the key parts of the crane boom, the calculation method is:

[0017] ;

[0018] In the formula Indicates the crane boom Theoretical load of key parts, Indicates the tilt angle of the crane boom in the pre-operation test, Indicates the mass of the object to be hoisted in the pre-operation test. represents the acceleration due to gravity, Indicates the crane boom The distance between the key parts and the base of the boom;

[0019] Then calculate the correction coefficient of each key part of the crane boom, the calculation method is:

[0020] ;

[0021] In the formula Indicates the crane boom Correction coefficients for key parts, Indicates the crane boom The total load collected from each key part, Indicates the total number of acquisitions in the pre-operation test;

[0022] The corrected total load of the key parts of the crane boom is expressed as:

[0023] ;

[0024] in Indicates the crane boom The key part is The corrected total load at the time of acquisition.

[0025] Preferably, the load matrix is ​​expressed as:

[0026] ;

[0027] In the formula, Indicated in In the first pre-operation test, the crane boom The key part is The corrected total load at the time of acquisition is Indicates The corresponding load matrix during the first pre-operation test; An index indicating the number of pre-job trials; Indicates the number of key parts of the crane boom;

[0028] The average matrix is ​​generated according to the load matrix corresponding to each pre-operation test, and the calculation method is:

[0029] ;

[0030] In the formula Represents the total number of pre-job trials.

[0031] Preferably, the logic for generating the fitting equation is:

[0032] The elements in the average matrix are analyzed horizontally to generate the fitting equation of the corrected total load of each key part with respect to the number of acquisitions. The fitting equation is expressed as:

[0033] ;

[0034] In the formula Indicates The fitting equation corresponding to the key parts is: represents the corrected total load as a function of the number of acquisitions, Represents the elements within the average matrix.

[0035] Preferably, the working condition data includes the mass of the load to be hoisted in the actual operation, the inclination angle of the crane boom, and the wind speed in the environment where the crane is located; the logic for generating the load safety factor is:

[0036] Calculate the theoretical load and wind load of different key parts of the crane boom in actual operation according to the working condition data, and call The average value of the correction coefficients of each key part in the pre-operation test is used to generate the corrected total load of the key parts of the crane boom in actual operation;

[0037] Then, according to the total load corrected at the key parts of the crane boom in actual operation, the corresponding load matrix and average matrix are generated, and the average matrix is ​​substituted into the fitting equation to predict the total load corrected at different time moments in actual operation;

[0038] Finally, the corrected total load predicted at different time moments is compared with the preset load threshold, and the load safety factor is generated according to the comparison result.

[0039] Preferably, the calculation formula of the load safety factor is:

[0040] ;

[0041] In the formula represents the load safety factor, represents the discriminant factor, Indicates the crane boom The load threshold corresponding to each key part is Indicates the actual operation of the fitting equation for the crane boom The key part is The corrected total load prediction for the time of acquisition.

[0042] Preferably, the logic of the value of the discrimination factor is: if the predicted total load after correction of all key parts of the crane boom at each acquisition is less than the corresponding load threshold, then ,otherwise .

[0043] Preferably, the load safety factor is compared with a preset factor threshold:

[0044] when When the load burden of the crane boom in this operation is considered to be large, the risk warning level is high;

[0045] when When the load burden of the crane boom in this operation is considered to be average, the risk warning level is medium;

[0046] when When the load burden of the crane boom in this operation is considered to be small, the risk warning level is low;

[0047] In the formula represents the preset coefficient threshold, and .

[0048] Compared with the prior art, the present invention has the following beneficial effects:

[0049] The present invention obtains actual data through pre-operation tests, combines wind speed, load matrix and dynamic factors to correct the load, and generates a fitting equation to predict future load conditions. Dynamic monitoring and accurate evaluation of the crane boom load are achieved, significantly improving the accuracy of risk management. Compared with traditional methods, this solution can predict the operating conditions and conduct risk assessment in advance, thereby preventing potential accidents and providing reliable safety protection for operators. This not only improves the safety of crane operations, but also optimizes equipment management and maintenance processes, providing an effective solution for high-risk operation scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 It is a schematic diagram of the overall method flow of the present invention. DETAILED DESCRIPTION

[0051] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with specific embodiments.

[0052] It should be noted that, unless otherwise defined, the technical terms or scientific terms used in the present invention should be understood by people with ordinary skills in the field to which the present invention belongs. The words "first", "second" and similar words used in the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. "Include" or "comprise" and similar words mean that the elements or objects appearing before the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. "Connect" or "connected" and similar words are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0053] Example:

[0054] See also Figure 1 , the present invention provides a technical solution:

[0055] A risk early warning method for a crane hoisting operation process, the specific steps comprising:

[0056] S1: Carry out a pre-operation test on the crane to be warned, and collect the total load of the key parts of the crane boom and the wind speed of the environment where the key parts of the crane boom are located in the pre-operation test.

[0057] During the pre-operation test, the same load to be lifted is hoisted at a constant speed at the same lifting speed. The total load of the key parts of the crane boom and the wind speed of the crane environment are collected during the hoisting process. This is repeated at least three times. The total load of the key parts of the crane boom and the wind speed of the crane environment are collected at the same frequency and the interval is 100%. .

[0058] In this step, the key parts of the crane boom include the hook, boom joints and other positions, and specific points can be added or deleted according to actual needs. It is understandable that in order to reduce the dynamic load brought by acceleration to the crane boom, the uniform speed lifting method is used for operation, but different dynamic loads will still be brought during operation due to vibration, equipment aging and other reasons.

[0059] Through pre-operation tests, data can be obtained in a real, controlled environment. Compared with methods that rely solely on simulation calculations, this type of data can better reflect potential problems in actual operations. Collecting load and wind speed data at key locations (such as hooks, boom joints, etc.) covers the main factors that may be affected during the crane hoisting process, provides a comprehensive analysis basis, and can provide on-site operators with more credible risk assessment and early warning information, thereby improving the effectiveness and practicality of the early warning system.

[0060] S2: According to the total load of the key parts of the crane boom and the wind speed of the environment, the total load of the key parts is corrected, the load matrix is ​​constructed according to the corrected total load, and the curve is fitted according to the load matrix to generate the corresponding fitting equation.

[0061] The logic for correcting the total load of key parts according to the wind speed in the environment where the crane is located is:

[0062] The wind load is calculated based on the wind speed in the environment where the key parts of the crane boom are located. The calculation method is:

[0063] ;

[0064] In the formula Indicates the crane boom The key part is The wind speed at the time of the first collection, Indicates the crane boom The key part is The wind load corresponding to the wind speed at the time of the first collection is Indicates the crane boom The windward area of ​​the key parts, represents the air density, Indicates the preset drag coefficient, The index indicating the number of collections. An index representing a key part of the crane boom.

[0065] It is understandable that due to the total load on the key parts of the crane boom and the wind speed in the environment where the crane is located, the two collection frequencies are the same and the interval time is Therefore, the number of acquisitions can be equivalent to the operation time, and the analysis of the number of acquisitions is equivalent to the analysis of the operation time. When calculating the wind load, the windward area of ​​different key parts can be calculated according to the specific dimensions of the place, which can be approximately equivalent to the area of ​​the widest surface. The determination of the drag coefficient usually needs to be determined based on the equipment parameters given by the crane manufacturer, or it can be determined based on the experience or experiments of the expert group.

[0066] Then calculate the theoretical load of the key parts of the crane boom, the calculation method is:

[0067] ;

[0068] In the formula Indicates the crane boom Theoretical load of key parts, Indicates the tilt angle of the crane boom in the pre-operation test, Indicates the mass of the object to be hoisted in the pre-operation test. represents the acceleration due to gravity, Indicates the crane boom The distance between the key parts and the root of the boom.

[0069] Then calculate the correction coefficient of each key part of the crane boom, the calculation method is:

[0070] ;

[0071] In the formula Indicates the crane boom Correction coefficients for key parts, Indicates the crane boom The total load collected from each key part, Indicates the total number of collections.

[0072] It can be seen from the calculation formula of the correction coefficient that the correction coefficient is a difference mean obtained from multiple collections, and this difference reflects the different dynamic load influences caused by vibration, equipment aging and other reasons after removing the wind load.

[0073] The corrected total load of the key parts of the crane boom is expressed as:

[0074] ;

[0075] in Indicates the crane boom The key part is The corrected total load at the time of acquisition.

[0076] It can be seen from the calculation formula of the corrected total load that the corrected total load is essentially a predicted value, and the collected total load is an actual value. This method based on the combination of measured data and theoretical calculations is more scientific and accurate than relying solely on experience and traditional theories.

[0077] The load matrix is ​​expressed as:

[0078] ;

[0079] In the formula, Indicated in In the first pre-operation test, the crane boom The key part is The corrected total load at the time of acquisition is Indicates The corresponding load matrix during the first pre-operation test; An index indicating the number of pre-job trials; Indicates the number of key parts of the crane boom;

[0080] The average matrix is ​​generated according to the load matrix corresponding to each pre-operation test, and the calculation method is:

[0081] ;

[0082] In the formula represents the total number of pre-job trials;

[0083] In this step, the wind load is calculated through a formula and separated from the total load. At the same time, the difference mean of multiple collections is also taken into account, so that it can reflect the impact of dynamic loads such as vibration and equipment aging on the total load. It can identify signs of excessive equipment vibration or aging in advance and provide decision support for equipment maintenance and management.

[0084] S3: Collect the working condition data of the crane during actual operation. The working condition data includes the mass of the load to be lifted, the tilt angle of the crane boom, and the wind speed in the environment where the crane is located. Generate a load safety factor based on the working condition data and the fitting equation, determine the risk level of the lifting operation based on the load safety factor, and generate a corresponding risk warning.

[0085] The logic for generating the fitting equation is:

[0086] The elements in the average matrix are analyzed horizontally to generate the fitting equation of the corrected total load of each key part with respect to the number of acquisitions. The fitting equation is expressed as:

[0087] ;

[0088] In the formula Indicates The fitting equation corresponding to the key parts is: represents the corrected total load as a function of the number of acquisitions, Represents the elements within the average matrix.

[0089] It is understandable that, since the number of acquisitions is strongly correlated with the operation time, the elements in the average matrix can equivalently reflect the changes in the corrected total load with respect to the operation time during the horizontal analysis and fitting. The specific function form can be fitted by a quadratic polynomial. By fitting the equation, the load conditions of key parts at future acquisition points can be predicted, and an evaluation standard can be provided so that users can dynamically monitor and evaluate load changes, and can more accurately calculate the load safety factor. In other words, in actual operations, before the official start of lifting, the measured working condition data can be used to evaluate and warn of the risks of this actual operation, so as to better understand the dynamic load conditions during the operation, and then optimize the risk management strategy.

[0090] The logic for generating the load safety factor is:

[0091] Calculate theoretical loads and wind loads at different key parts of the crane boom in actual operation based on working condition data;

[0092] Then, the corrected total load in different time periods during actual operation is predicted based on the fitting equation;

[0093] Finally, the corrected total load predicted in different time periods is compared with the preset load threshold, and the load safety factor is generated according to the comparison result.

[0094] The calculation formula for load safety factor is:

[0095] ;

[0096] In the formula represents the load safety factor, represents the discriminant factor, Indicates the crane boom The load threshold corresponding to each key part is Indicates that the fitting equation is applied to the key part of the crane boom in actual operation. The corrected total load prediction for the time of acquisition.

[0097] The logic of the discriminant factor is: if the predicted total load after correction of all key parts of the crane boom at each acquisition is less than the corresponding load threshold, then ,otherwise .

[0098] From the calculation formula of the load safety factor, it can be seen that the load safety factor is a risk prediction of the entire actual operation process of the crane, reflecting the load bearing condition of the crane boom. The larger the load safety factor, the farther the total load predicted each time during the actual operation is from the load threshold, in other words, it is safer. The setting of the discrimination factor ensures that the total load will not exceed the standard during the entire actual operation process, further improving the real-time and accuracy of risk assessment.

[0099] Compare the load safety factor to a preset factor threshold:

[0100] when When the load burden of the crane boom in this operation is considered to be large, the risk warning level is high;

[0101] when When the load burden of the crane boom in this operation is considered to be average, the risk warning level is medium;

[0102] when When the load burden of the crane boom in this operation is considered to be small, the risk warning level is low;

[0103] In the formula represents the preset coefficient threshold, and .

[0104] In this step, the actual working condition data (such as the mass of the load to be lifted, the tilt angle of the boom, and the ambient wind speed) are combined for evaluation, so that the risk assessment can dynamically reflect the immediate status of the operation. At the same time, the corrected total load is predicted by fitting equations, which is closely integrated with the actual operation to improve the real-time and accuracy of the evaluation, avoid accidents caused by overloading or improper operation, and provide higher safety protection for operators.

[0105] In summary, the present invention obtains actual data through pre-operation tests, combines wind speed, load matrix and dynamic factors to correct the load, and generates a fitting equation to predict future load conditions. Dynamic monitoring and accurate evaluation of the crane boom load are achieved, significantly improving the accuracy of risk management. Compared with traditional methods, this solution can predict the operating conditions and conduct risk assessment in advance, thereby preventing potential accidents and providing reliable safety protection for operators. This not only improves the safety of crane operations, but also optimizes equipment management and maintenance processes, providing an effective solution for high-risk operation scenarios.

[0106] The above formulas are all dimensionless and numerical calculations. The formula is a formula for the most recent real situation obtained by collecting a large amount of data and performing software simulation. The preset parameters in the formula are set by technicians in this field according to actual conditions.

[0107] The above embodiments may be implemented in whole or in part by software, hardware, firmware or any other combination thereof. When implemented by software, the above embodiments may be implemented in whole or in part in the form of a computer program product. Those skilled in the art may appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein may be implemented by electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed by hardware or software methods depends on the specific application and design constraints of the technical solution.

[0108] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, and may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0109] The above description is only a specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application.

Claims

1. A risk warning method for crane hoisting operation process, characterized in that: The specific steps include: S1: Conduct a pre-operation test based on the crane to be warned, and collect the total load of the key parts of the crane boom and the wind speed of the environment where the key parts of the crane boom are located during the pre-operation test; S2: According to the wind speed of the environment where the key parts of the crane boom are located, the total load of the key parts is corrected, the load matrix is ​​constructed according to the corrected total load, and the curve fitting is performed according to the load matrix to generate the corresponding fitting equation; The logic for correcting the total load of key parts according to the wind speed in the environment where the crane is located is: The wind load is calculated based on the wind speed in the environment where the key parts of the crane boom are located. The calculation method is: In the formula Indicates the crane boom The key part is The wind speed at the time of the first collection, Indicates the crane boom The key part is The wind load corresponding to the wind speed at the time of the first collection is Indicates the crane boom The windward area of ​​the key parts, represents the air density, Indicates the preset drag coefficient, The index indicating the number of collections. Indicates the index of the key parts of the crane boom; Then calculate the theoretical load of the key parts of the crane boom, the calculation method is: In the formula Indicates the crane boom Theoretical load of key parts, Indicates the tilt angle of the crane boom in the pre-operation test, Indicates the mass of the object to be hoisted in the pre-operation test. represents the acceleration due to gravity, Indicates the crane boom The distance between the key parts and the base of the boom; Then calculate the correction coefficient of each key part of the crane boom, the calculation method is: In the formula Indicates the crane boom Correction coefficients for key parts, Indicates the crane boom The total load collected from each key part, Indicates the total number of acquisitions in the pre-operation test; The corrected total load of the key parts of the crane boom is expressed as: in Indicates the crane boom The key part is The corrected total load at the time of acquisition; S3: Collect the working condition data of the crane during actual operation, generate the load safety factor based on the working condition data and the fitting equation, judge the risk level of the lifting operation according to the load safety factor, and generate the corresponding risk warning; The working condition data includes the mass of the load to be hoisted in the actual operation, the tilt angle of the crane boom, and the wind speed in the environment where the crane is located; the logic for generating the load safety factor is: The theoretical load and wind load of different key parts of the crane boom in actual operation are calculated according to the working condition data, and the average value of the correction coefficient of each key part in P pre-operation tests is called to generate the corrected total load of the key parts of the crane boom in actual operation; Then, according to the total load corrected at the key parts of the crane boom in actual operation, the corresponding load matrix and average matrix are generated, and the average matrix is ​​substituted into the fitting equation to predict the total load corrected at different time moments in actual operation; Finally, the corrected total load predicted at different time moments is compared with the preset load threshold, and the load safety factor is generated according to the comparison result.

2. A crane hoisting operation process risk early warning method according to claim 1, characterized in that: The key parts of the crane boom include the hook and the boom joint. Each time the pre-operation test is carried out, the same load to be lifted is hoisted at a uniform speed at the same lifting speed, and the pre-operation test is repeated at least three times. In each pre-operation test, the same time interval is used to At the same time, the total load of the key parts of the crane boom and the wind speed in the environment where the crane is located are collected.

3. A crane hoisting operation process risk early warning method according to claim 2, characterized in that: The load matrix is ​​expressed as: In the formula, Indicated in In the first pre-operation test, the crane boom The key part is The total load corrected during the acquisition, Indicates The corresponding load matrix during the first pre-operation test; An index indicating the number of pre-job trials; Indicates the number of key parts of the crane boom; The average matrix is ​​generated according to the load matrix corresponding to each pre-operation test, and the calculation method is: In the formula Represents the total number of pre-job trials.

4. A crane hoisting operation process risk early warning method according to claim 3, characterized in that: The logic for generating the fitting equation is: The elements in the average matrix are analyzed horizontally to generate the fitting equation of the corrected total load of each key part with respect to the number of acquisitions. The fitting equation is expressed as: In the formula Indicates The fitting equation corresponding to the key parts is: represents the corrected total load as a function of the number of acquisitions, Represents the elements within the average matrix.

5. A crane hoisting operation process risk early warning method according to claim 4, characterized in that: The calculation formula of the load safety factor is: In the formula represents the load safety factor, represents the discriminant factor, Indicates the crane boom The load threshold corresponding to each key part is Indicates the actual operation of the fitting equation for the crane boom The key part is The corrected total load prediction for the time of acquisition.

6. A crane hoisting operation process risk early warning method according to claim 5, characterized in that: The logic of the value of the discrimination factor is: if the predicted total load after correction of all key parts of the crane boom at each acquisition is less than the corresponding load threshold, then ,otherwise .

7. A crane hoisting operation process risk early warning method according to claim 6, characterized in that: Compare the load safety factor to a preset factor threshold: when When the load burden of the crane boom in this operation is considered to be large, the risk warning level is high; when When the load burden of the crane boom in this operation is considered to be average, the risk warning level is medium; when When the load burden of the crane boom in this operation is considered to be small, the risk warning level is low; In the formula represents the preset coefficient threshold, and .

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