Intelligent monitoring system and method for steel wire rope of large hoisting equipment in high-speed rail beam field

Abstract

The invention discloses an intelligent monitoring system and method for a steel wire rope of large hoisting equipment in a high-speed rail beam field, and the system comprises a magnetizer, a magnetic flux leakage sensor, an acquisition terminal and an informatization platform, the magnetizer and the magnetic flux leakage sensor are installed at a top installation beam at an interval and can pass through a vertical section of the steel wire rope, and the magnetic flux leakage sensor is connected to the data acquisition terminal. The data acquisition terminal is connected to the informatization platform, the informatization platform is provided with a steel wire rope monitoring system, and the steel wire rope monitoring system is provided with a data processing module, a data analysis and comparison module and a data alarm reminding module. According to the invention, whole-course monitoring and early warning can be carried out on the steel wire ropes of numerous heavy hoisting equipment in a beam yard, the use safety is improved, the occurrence probability of safety accidents is reduced, intelligence is realized, the production efficiency is improved, real-time online reading of data can be realized, and intelligent monitoring and early warning of the steel wire ropes in the full life use cycle are realized.

Description

Technical Field

[0001] The invention belongs to the technical field of intelligent monitoring of steel wire ropes, and relates to an intelligent monitoring system and method for steel wire ropes of large-scale hoisting equipment in a high-speed railway beam yard. Background Art

[0002] The safety of large-scale hoisting equipment has always been a top priority in engineering projects. It is a top priority that cannot be ignored. The wire ropes on large-scale hoisting equipment will inevitably experience fatigue, rust, wear and even sudden breakage during use, resulting in a decrease in carrying capacity. If the use method is unreasonable, there is a lack of safety inspection, no maintenance, or even the use of scrapped wire ropes, it may cause major production safety accidents. At present, the management of wire ropes on large-scale hoisting equipment has always been in an embarrassing situation where it is valued but there is no effective means. Traditional methods such as manual visual inspection and vernier caliper measurement of the wear section are usually used to compare the measured value with the original value of the new rope. The difference is the wear amount of the wire rope section. This traditional method based on experience and feeling has many problems: First, it is inefficient. The traditional inspection method of manual inspection, hand touch, and caliper measurement is time-consuming and inefficient. Moreover, this method is acceptable for measuring the size of new wire ropes, but the data for testing wire ropes in use is extremely inaccurate and cannot meet the requirements for the detection and use of wire ropes. Second, the means are backward. The inherent unreliability of manual inspection makes it difficult to detect major accident hazards. 12% of in-service wire ropes are in an uncontrolled "dangerous or extremely dangerous" state. The third is economic waste. Regular replacement causes great waste. More than 70% of "retired" wire ropes are in the running-in period and still have normal use value.

[0003] During the railway construction process, the box beam prefabrication yard is used to prefabricate the box beam in advance. Many box beams are required, but the construction period is short. The traditional box beam casting is difficult to meet the requirements. Intelligent technology is needed to achieve full-process monitoring. The wire rope is an important component of the large-scale lifting equipment in the beam yard (such as the beam yard equipped with 80t gantry cranes, 1000t beam lifting machines, 1000t bridge erection machines and other large-scale special equipment). The weight of the wire rope during the lifting process is several hundred tons. The safety of its lifting is particularly important. It is difficult to meet the full-process safety monitoring by manual labor. The Chinese patent application "202410915127X" provides a device and method for non-destructive flaw detection of elevator wire ropes, which uses magnetization for leakage magnetic detection. When a large number of heavy lifting equipment are used in the beam yard, it is difficult to meet the full-process safety monitoring and early warning functions. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide an intelligent monitoring system and method for steel wire ropes of large-scale lifting equipment in a high-speed railway beam yard, which can perform full-process monitoring and early warning on the steel wire ropes of numerous heavy lifting equipment in the beam yard, improve safety of use, reduce the probability of safety accidents, realize intelligence, and improve production efficiency.

[0005] The technical solution adopted by the present invention is: an intelligent monitoring system for wire ropes of large-scale hoisting equipment in a high-speed railway beam yard, including a magnetizer, a leakage magnetic sensor, a collection terminal and an information platform. The magnetizer and the leakage magnetic sensor are installed at intervals on the top mounting beam and can pass through the vertical section of the wire rope. The leakage magnetic sensor is connected to the data collection terminal, and the data collection terminal is connected to the information platform. The information platform is provided with a wire rope monitoring system. The wire rope monitoring system is provided with a data processing module, a data analysis and comparison module and a data alarm reminder module. The data processing module is used to pre-process the data collected by the leakage magnetic sensor, the data analysis and comparison module is used to compare the collected data with a set threshold value to determine whether the data error size meets the requirements, and the alarm reminder module is used to alarm and remind the data exceeding the set threshold value.

[0006] Furthermore, the steel wire rope segments corresponding to both sides of the magnetized body and the magnetic flux leakage sensor are installed with double positioning guide wheels, and the double positioning guide wheels include a first guide wheel and a second guide wheel. The first guide wheel and the second guide wheel are arranged alternately and rotatably connected to the positioning guide wheel frame. The positioning guide wheel frame is fixedly connected to the top mounting beam of the lifting equipment. The two pairs of first guide wheels and second guide wheels can allow the steel wire rope coming out of the magnetized body to be squeezed and straightened.

[0007] Furthermore, the above-mentioned intelligent monitoring system for wire ropes of large-scale hoisting equipment in a high-speed railway beam yard also includes two demagnetizers, which are installed on the top mounting beam and are respectively located between the magnetized body and the wire rope hoist and between the leakage magnetic sensor and the wire winding drum.

[0008] Furthermore, the above-mentioned leakage magnetic sensor is connected to the top mounting beam through a shock-absorbing frame, and the shock-absorbing frame includes a fixed plate, a cantilever shock-absorbing box and a mounting plate. The fixed plate and the mounting plate are fixedly connected at both ends of the cantilever shock-absorbing box in an I-shape. A shock-absorbing rubber pad is installed between the fixed plate and the leakage magnetic sensor, and the mounting plate is connected to the top mounting beam through a shock-absorbing rubber. A partition chamber is arranged in the cantilever shock-absorbing box, and shock-absorbing steel balls of different sizes are placed in the partition chamber.

[0009] Furthermore, the above-mentioned intelligent monitoring system for steel wire ropes of large-scale hoisting equipment in a high-speed railway beam yard also includes a TST flaw detection equipment cloud platform, the data acquisition terminal is connected to the TST flaw detection equipment cloud platform, and the TST flaw detection equipment cloud platform is connected to the information platform.

[0010] Furthermore, the above-mentioned intelligent monitoring system for wire ropes of large-scale hoisting equipment in a high-speed railway beam yard also includes a wire rope released length measuring device and a position marking module. The wire rope released length measuring device is used to measure the wire rope released length. The wire rope released length measuring device is connected to the data acquisition terminal. The position marking module is used to find damage marks of the damaged position relative to the reference point during the non-destructive testing process of the wire rope released length. The damage mark is the distance of the damaged position relative to the reference point.

[0011] Furthermore, the above-mentioned intelligent monitoring system for steel wire ropes of large-scale hoisting equipment in a high-speed railway beam yard also includes a mobile phone APP terminal, and the mobile phone AAP terminal is connected to the TST flaw detection equipment cloud platform.

[0012] A monitoring method for a steel wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard, the method is as follows: 1) Risk level classification: multiple risk levels are divided according to the wire rope wear value; 2) Set the initial position of the magnetic flux leakage sensor installed on the wire rope monitored by each lifting equipment, which is the reference point; 3) Collect the magnetic leakage sensor data installed on all hoisting equipment in the beam yard; 4) Upload the collected data to the TST flaw detection equipment cloud platform; 5) Use the data processing module to extract data from the TST flaw detection equipment cloud platform for preprocessing; 6) Compare and analyze the pre-processed data to determine whether the data is greater than the alarm threshold. If it is greater than the TST flaw detection equipment cloud platform, an alarm will be issued and classified into the corresponding alarm risk level. The location information of the wire rope will be tracked, and a pop-up window will automatically display the risk level and location information of the damaged wire rope, and the risk level and location information of the damaged wire rope will be stored in the damaged wire rope risk level and location information; 7) Verify and handle the wire rope according to the risk level and location information; 8) After verification, replace the corresponding wire rope.

[0013] Furthermore, the risk level and location information of the damaged wire rope in the above step 6) are read through the mobile phone APP, and the alarm information is uploaded to the management personnel and on-site personnel, who verify and handle the information accordingly.

[0014] Furthermore, after the verification in the above step 8) is correct, it also includes changing the lifting site to carry out the repositioning and lifting of the box girder.

[0015] The beneficial effects of the present invention are as follows: compared with the prior art, the present invention magnetizes the steel wire rope through a magnetizer, and uses a leakage magnetic sensor arranged at intervals from the magnetizer to detect magnetic flux. If a data mutation occurs and exceeds a set threshold, an early warning is issued. The steel wire ropes of numerous heavy lifting equipment in a beam yard can be monitored and warned throughout the entire process, thereby improving safety in use, reducing the probability of safety accidents, achieving intelligence, and improving production efficiency. The magnetizer and the leakage magnetic sensor are installed at intervals, which can avoid the influence of the strong magnetic field of the magnetizer on the detection of the leakage magnetic sensor and improve the detection accuracy. The steel wire rope monitoring system can realize full-process intelligent monitoring, can realize real-time online reading of data, and realize intelligent monitoring and early warning of the entire life cycle of the steel wire rope. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the installation structure of the magnetized body and the magnetic flux leakage sensor; Figure 2 This is a connection diagram of the monitoring system; Figure 3 This is a flow chart of the intelligent monitoring method for steel wire ropes of large hoisting equipment in a high-speed railway box girder prefabrication yard. DETAILED DESCRIPTION

[0017] The invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0018] Example 1: Reference Figure 1-3 As shown, a wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard includes a magnetizer 1, a leakage magnetic sensor 2, a collection terminal 3 and an information platform 4. The magnetizer 1 and the leakage magnetic sensor 2 are installed at intervals on the top mounting beam 5, and the U-shaped openings of the magnetizer 1 and the leakage magnetic sensor 2 can pass through the vertical section of the wire rope 11. The leakage magnetic sensor 2 is connected to the data collection terminal 3, and the data collection terminal 3 is connected to the information platform 4. The information platform 4 is provided with a wire rope monitoring system, and the wire rope monitoring system is provided with a data processing module, a data analysis and comparison module and a data alarm reminder module. The data processing module is used to pre-process the data collected by the leakage magnetic sensor, the data analysis and comparison module is used to compare the collected data with a set threshold value to determine whether the data error meets the requirements, and the alarm reminder module is used to alarm the data exceeding the set threshold value.

[0019] A magnetizer and a sensor are installed on each wire rope of large hoisting equipment. The two monitoring instruments are small in size and have no strict requirements on the installation environment, so they are easy to install. The back of the magnetizer and the sensor housing are designed with φ9mm, 20mm deep threaded mounting holes. Just make sure that there is a fixed mounting plate at the set distance from the center of the wire rope to be inspected. During installation, drill a φ9mm through hole on the steel plate according to the spacing requirements between the sensor and the magnetizer and the spacing between the mounting holes on their respective housings, and use M8 screws of appropriate length to pass through the steel plate to fix the magnetizer and sensor. During installation, the N and S polarities of the magnetizer and the sensor should be consistent along the direction of the wire rope.

[0020] In order to improve the detection accuracy and avoid the problem of large detection data errors caused by shaking, double positioning guide wheels 6 are installed on the corresponding wire rope segments on both sides of the magnetized body 1 and the leakage magnetic sensor 2. The double positioning guide wheels 6 include a first guide wheel 601 and a second guide wheel 602. The first guide wheel 601 and the second guide wheel 602 are arranged alternately and rotatably connected to the positioning guide wheel frame 603. The positioning guide wheel frame 603 is fixedly connected to the top mounting beam 5 of the lifting equipment. The two pairs of first guide wheels 601 and second guide wheels 602 can allow the wire rope of the magnetized body 1 to be squeezed and straightened.

[0021] In order to avoid the large and strong magnetic field formed by the winding of the wire rope after the magnetized wire rope affects the normal use of electronic devices, an intelligent monitoring system for wire rope of large lifting equipment in a high-speed railway beam yard also includes two demagnetizers 7. The two demagnetizers 7 are installed on the top mounting beam 5 and are respectively located between the magnetized body 1 and the wire rope sling and between the leakage magnetic sensor 2 and the wire winding drum. By installing the demagnetizer, the wire rope after the leakage magnetic detection is demagnetized to avoid the large magnetic field formed by winding on the wire rope winding drum. The wire rope can also be demagnetized after passing through the magnetized body during the lowering of the sling. After the overall demagnetization, the on-site dust is prevented from being adsorbed on the wire rope, thereby improving the stability of the wire rope.

[0022] In order to improve the detection stability of the leakage magnetic sensor, the leakage magnetic sensor 2 is connected to the top mounting beam 5 through a shock absorbing frame 8. The shock absorbing frame 8 includes a fixed plate 801, a cantilever shock absorbing box 802 and a mounting plate 803. The fixed plate 801 and the mounting plate 803 are fixedly connected to the two ends of the cantilever shock absorbing box 802 in an I-shape. A shock absorbing rubber pad 804 is installed between the fixed plate 801 and the leakage magnetic sensor 2. The mounting plate 803 is connected to the top mounting beam 5 through a shock absorbing rubber 805. A partition chamber is arranged in the cantilever shock absorbing box 802. Shock absorbing steel balls of different sizes are placed in the partition chamber. The cantilever shock absorbing box can provide a better damping effect, greatly reduce the vibration amplitude, and achieve a better shock absorbing effect. In combination with the shock absorbing rubber pads and shock absorbing rubber at both ends, it can achieve multiple and multi-directional shock absorbing effects, further improving the detection stability of the leakage magnetic sensor and improving the detection accuracy.

[0023] In order to facilitate data use and quick reading, a high-speed railway beam yard large-scale lifting equipment wire rope intelligent monitoring system also includes a TST flaw detection equipment cloud platform 9, and the data acquisition terminal 3 is connected to the TST flaw detection equipment cloud platform 9. The data collected by the acquisition terminal is quickly uploaded through the Internet of Things card to improve efficiency and data processing efficiency. The TST flaw detection equipment cloud platform 9 is connected to the information platform 4.

[0024] In order to accurately locate and detect the damage position, a wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard also includes a wire rope release length measuring device and a position marking module. The wire rope release length measuring device is used to measure the wire rope release length. The wire rope release length measuring device is connected to a data acquisition terminal 3. The position marking module is used to find a damage mark of the damage position relative to the reference point during the non-destructive flaw detection process of the wire rope release length. The damage mark is the distance of the damage position relative to the reference point. Through length measurement, the distance relative to the reference point can be changed, thereby accurately detecting the damage position, and automatically marking the position information through the position marking module. The annotated information includes the hoisting equipment serial number, the specific monitoring wire rope of the hoisting declaration serial number, the damage location and its damage value, the alarm level, the monitoring time, etc. The annotated information can quickly and timely understand the equipment and specific location of the corresponding wire rope damage, so as to quickly notify the corresponding equipment management personnel for processing, improve the processing efficiency, improve the hoisting efficiency and the conversion efficiency of the hoisting site. The wire rope release length measuring device adopts a rotary encoder for measurement. The rotary encoder is installed on the positioning guide wheel frame through a fixed frame and the rotating axis of the rotary encoder is on the axle of one of the guide wheels. The number of rotations is measured and converted into a straight line distance to achieve length measurement.

[0025] For the convenience of management, a high-speed railway beam yard large-scale lifting equipment wire rope intelligent monitoring system also includes a mobile phone APP terminal 10, and the mobile phone AAP terminal 10 is connected to the TST flaw detection equipment cloud platform 9. Project managers all have a real-name authenticated mobile phone APP terminal account. The APP software of the mobile phone APP terminal is synchronized with the data of the beam yard information platform. The mobile phone APP software can also display the equipment list, wire rope evaluation overview and monitoring details of each wire rope. When the wire rope wear value exceeds the set alarm threshold, the alarm information will be pushed to the relevant management personnel in real time through the mobile phone APP software. The management personnel can grasp the wire rope wear condition at the first time, check and replace the wire rope in time, eliminate safety hazards, and ensure construction safety.

[0026] Working Principle The leakage magnetic field produced by the surface breakage of the wire rope, or the local magnetic field mutation information caused by internal damage and excessive fatigue. This information represents or maps the various damages of the components and the fact that the materials fail abnormally. These abnormal information are extracted through full magnetic technology, filtered and analyzed using the correct recognition mode and mathematical model, and the magnetized body installed on the wire rope is used to magnetize the chaotic magnetic field signal inside the wire rope to be inspected into an overall uniform and detectable magnetic field. Then, the wear condition is collected in real time through the sensor installed on the wire rope, and the quantitative flaw detection of ferromagnetic components is realized. The digital signal with the wire rope damage information is transmitted and connected to the beam field information platform, and effective monitoring is implemented through the information platform and mobile phone APP.

[0027] Embodiment 2: A monitoring method of a steel wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard, the method is as follows: 1) Risk level classification: multiple risk levels are divided according to the wire rope wear value; 2) Set the initial position of the magnetic flux leakage sensor installed on the wire rope monitored by each lifting equipment, which is the reference point; 3) Collect the magnetic leakage sensor data installed on all hoisting equipment in the beam yard; 4) Upload the collected data to the TST flaw detection equipment cloud platform; 5) Use the data processing module to extract data from the TST flaw detection equipment cloud platform for preprocessing; 6) Compare and analyze the pre-processed data to determine whether the data is greater than the alarm threshold. If it is greater than the TST flaw detection equipment cloud platform, an alarm will be issued and classified into the corresponding alarm risk level. The location information of the wire rope will be tracked, and a pop-up window will automatically display the risk level and location information of the damaged wire rope, and the risk level and location information of the damaged wire rope will be stored in the damaged wire rope risk level and location information; 7) Verify and handle the wire rope according to the risk level and location information; 8) After verification, replace the corresponding wire rope.

[0028] In step 6), the risk level and location information of the damaged wire rope are read through the mobile phone APP, and the alarm information is uploaded to the management personnel and on-site personnel. The management personnel and on-site personnel verify and take corresponding measures.

[0029] After verification in step 8), it also includes changing the lifting site to carry out the repositioning and lifting of the box girder.

[0030] The above description is only a specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. An intelligent monitoring system for steel wire ropes of large hoisting equipment in a high-speed railway beam yard, characterized by: The invention comprises a magnetized body (1), a magnetic flux leakage sensor (2), a data acquisition terminal (3) and an information platform (4). The magnetized body (1) and the magnetic flux leakage sensor (2) are installed at intervals on a top mounting beam (5) and are capable of passing through a vertical section of a steel wire rope (11). The magnetic flux leakage sensor (2) is connected to the data acquisition terminal (3), and the data acquisition terminal (3) is connected to the information platform (4). The information platform (4) is provided with a steel wire rope monitoring system. The steel wire rope monitoring system is provided with a data processing module, a data analysis and comparison module and a data alarm reminder module. The data processing module is used for pre-processing data collected by the magnetic flux leakage sensor. The data analysis and comparison module is used for comparing the collected data with a set threshold value to determine whether the data error size meets the requirements. The alarm reminder module is used for alarming data exceeding the set threshold value.

2. According to claim 1, a high-speed railway beam yard large-scale lifting equipment wire rope intelligent monitoring system is characterized by: The steel wire rope segments corresponding to both sides of the magnetized body (1) and both sides of the magnetic flux leakage sensor (2) are both installed with double positioning guide wheels (6), the double positioning guide wheels (6) comprising a first guide wheel (601) and a second guide wheel (602), the first guide wheels (601) and the second guide wheels (602) being arranged alternately and rotatably connected to a positioning guide wheel frame (603), the positioning guide wheel frame (603) being fixedly connected to a top mounting beam (5) of the lifting equipment, and the two pairs of first guide wheels (601) and second guide wheels (602) can allow the steel wire rope of the magnetized body (1) to be in an extruded and straightened state.

3. According to claim 2, a high-speed railway beam yard large-scale hoisting equipment wire rope intelligent monitoring system is characterized by: It also includes two demagnetizers (7), which are mounted on the top mounting beam (5) and are respectively located between the magnetized body (1) and the wire rope hanger and between the magnetic flux leakage sensor (2) and the wire winding drum.

4. According to claim 3, a high-speed railway beam yard large-scale lifting equipment wire rope intelligent monitoring system is characterized by: The magnetic flux leakage sensor (2) is connected to the top mounting beam (5) via a shock absorbing frame (8); the shock absorbing frame (8) comprises a fixed plate (801), a cantilever shock absorbing box (802) and a mounting plate (803); the fixed plate (801) and the mounting plate (803) are fixedly connected to the two ends of the cantilever shock absorbing box (802) in an I-shape; a shock absorbing rubber pad (804) is installed between the fixed plate (801) and the magnetic flux leakage sensor (2); the mounting plate (803) and the top mounting beam (5) are connected via a shock absorbing rubber (805); a partition cavity is arranged in the cantilever shock absorbing box (802), and shock absorbing steel balls of different sizes are placed in the partition cavity.

5. According to claim 4, a high-speed railway beam yard large-scale hoisting equipment wire rope intelligent monitoring system is characterized by: It also includes a TST flaw detection equipment cloud platform, a data acquisition terminal (3) connected to the TST flaw detection equipment cloud platform, and the TST flaw detection equipment cloud platform connected to the information platform.

6. The intelligent monitoring system for steel wire ropes of large-scale hoisting equipment in a high-speed railway beam yard according to claim 4 is characterized by: It also includes a wire rope pay-out length measuring device and a position marking module. The wire rope pay-out length measuring device is used to measure the wire rope pay-out length. The wire rope pay-out length measuring device is connected to a data acquisition terminal (3). The position marking module is used to mark the damage position relative to the reference point of the wire rope pay-out length during non-destructive testing. The damage mark is the distance of the damage position relative to the reference point.

7. The intelligent monitoring system for steel wire ropes of large-scale hoisting equipment in a high-speed railway beam yard according to claim 6 is characterized by: It also includes a mobile APP and a mobile AAP connected to the TST flaw detection equipment cloud platform.

8. The monitoring method of a steel wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard according to claim 1 is characterized by: The method is as follows: 1) Risk level classification: multiple risk levels are divided according to the wire rope wear value; 2) Set the initial position of the magnetic flux leakage sensor installed on the wire rope monitored by each lifting equipment, which is the reference point; 3) Collect the magnetic leakage sensor data installed on all hoisting equipment in the beam yard; 4) Upload the collected data to the TST flaw detection equipment cloud platform; 5) Use the data processing module to extract data from the TST flaw detection equipment cloud platform for preprocessing; 6) Compare and analyze the pre-processed data to determine whether the data is greater than the set alarm threshold. If it is greater than the TST flaw detection equipment cloud platform, an alarm will be issued and classified into the corresponding alarm risk level. The location information of the wire rope will be tracked, and a pop-up window will automatically display the risk level and location information of the damaged wire rope, and the risk level and location information of the damaged wire rope will be stored in the damaged wire rope risk level and location information; 7) Verify and handle the wire rope according to the risk level and location information; 8) After verification, replace the corresponding wire rope.

9. The monitoring method of a steel wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard according to claim 8 is characterized by: In step 6), the risk level and location information of the damaged wire rope are read through the mobile phone APP, and the alarm information is uploaded to the management personnel and on-site personnel. The management personnel and on-site personnel verify and take corresponding measures.

10. The monitoring method of a steel wire rope intelligent monitoring system for large-scale hoisting equipment in a high-speed railway beam yard according to claim 8, characterized in that: After verification in step 8), it also includes changing the lifting site to carry out the repositioning and lifting of the box girder.

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