A smart monitoring system and method for wire ropes of large hoisting equipment in high-speed railway beam yards

Abstract

This invention discloses an intelligent monitoring system and method for wire ropes of large hoisting equipment in high-speed railway beam yards. The system includes a magnetizer, a magnetic flux leakage sensor, a data acquisition terminal, and an information platform. The magnetizer and the magnetic flux leakage sensor are installed alternately on the top mounting beam at vertical sections through which the wire rope passes. The magnetic flux leakage sensor is connected to the data acquisition terminal, which is connected to the information platform. The information platform is equipped with a wire rope monitoring system, which includes a data processing module, a data analysis and comparison module, and a data alarm and reminder module. This invention enables full-process monitoring and early warning of wire ropes for numerous heavy hoisting equipment in beam yards, improving operational safety, reducing the probability of accidents, achieving intelligent operation, improving production efficiency, and enabling real-time online data reading. It achieves intelligent monitoring and early warning throughout the entire life cycle of the wire rope.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of steel wire rope intelligent monitoring, and relates to a high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system and method. BACKGROUND

[0002] In engineering projects, the safety of large hoisting equipment is always the top priority and cannot be ignored. The steel wire ropes on the large hoisting equipment will inevitably appear fatigue, rust, wear and even breakage during use, which will lead to a decrease in carrying capacity. If the use method is unreasonable, safety inspection is lacking, maintenance is not performed, or even scrap steel wire ropes are used, etc., major production safety accidents may be caused. At present, the management of the steel wire ropes on the large hoisting equipment is always in an embarrassing situation of paying attention but having no effective means. The traditional manual visual inspection and vernier caliper measurement of the wear section are usually used. The measured value is compared with the original value of the new rope, and the difference is the wear amount of the steel wire rope section. This traditional method based on experience and feeling has many problems: first, the efficiency is low. The traditional inspection method is time-consuming and inefficient, and the data of the steel wire ropes in use is extremely inaccurate, which cannot meet the detection requirements of the steel wire ropes. Second, the means are backward. The inherent unreliability of manual detection makes it difficult to find major accident hazards, and 12% of the in-service steel wire ropes are in a dangerous or extremely dangerous state without control. Third, there is economic waste. Regular replacement causes great waste, and more than 70% of the “retired” steel wire ropes are still in the running-in period and have normal use value.

[0003] In the process of railway construction, box girder precast beam field is used to precast box girder in advance. The required box girder is much, but the construction period is short. The traditional box girder pouring cannot meet the requirements, and intelligent technology is needed to realize full-process monitoring. The steel wire rope is an important component of the large hoisting equipment (such as the beam field equipped with 80t gantry crane, 1000t beam lifting machine, 1000t bridge erecting machine and other large special equipment). The safety of hoisting is particularly important, and manual inspection cannot meet the requirements of full-process safety monitoring. The Chinese patent application “202410915127X” provides a device and method for nondestructive testing of elevator steel wire ropes. The device adopts magnetic leakage detection after magnetization. However, when heavy hoisting equipment is used in the beam field, it is difficult to meet the requirements of full-process safety monitoring and early warning. SUMMARY

[0004] The technical problem to be solved by the application is to provide a high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system and method, which can monitor and warn the steel wire ropes of the numerous heavy hoisting equipment in the beam field, improve the use safety, reduce the probability of safety accidents, realize intelligentization and improve the production efficiency.

[0005] The technical solution adopted in this invention is as follows: an intelligent monitoring system for steel wire ropes of large hoisting equipment in high-speed railway beam yards, including a magnetizer, a magnetic leakage sensor, a data acquisition terminal, and an information platform. The magnetizer and the magnetic leakage sensor are installed alternately on the top mounting beam and at the vertical section through which the steel wire rope can pass. The magnetic leakage sensor is connected to the data acquisition terminal, and the data acquisition terminal is connected to the information platform. The information platform is equipped with a steel wire rope monitoring system, which includes a data processing module, a data analysis and comparison module, and a data alarm and reminder module. The data processing module is used to preprocess the data collected by the magnetic leakage sensor. The data analysis and comparison module is used to compare the collected data with a set threshold to determine whether the data error meets the requirements. The alarm and reminder module is used to issue an alarm and reminder for data exceeding the set threshold.

[0006] Furthermore, the steel wire rope segments corresponding to both sides of the magnetizer and both sides of the leakage magnetic sensor are equipped with dual positioning guide wheels. The dual 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 hoisting equipment. The two pairs of first guide wheels and second guide wheels can make the steel wire rope of the magnetizer form a squeezed and taut state.

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

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

[0009] Furthermore, the aforementioned intelligent monitoring system for steel wire ropes of large hoisting equipment in high-speed railway beam yards also includes a TST flaw detection equipment cloud platform, with data acquisition terminals connected to the TST flaw detection equipment cloud platform, and the TST flaw detection equipment cloud platform connected to an information platform.

[0010] Furthermore, the aforementioned intelligent monitoring system for wire ropes of large hoisting equipment in high-speed railway beam yards 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 release length of the wire rope and is connected to a data acquisition terminal. The position marking module is used to mark the damage location of the wire rope release length during non-destructive testing relative to the reference point. The damage mark is the distance of the damage location relative to the reference point.

[0011] Furthermore, the aforementioned intelligent monitoring system for steel wire ropes of large hoisting equipment in high-speed railway beam yards also includes a mobile APP, which is connected to the TST flaw detection equipment cloud platform.

[0012] A monitoring method for an intelligent monitoring system of wire ropes in large hoisting equipment at high-speed railway beam yards, the method is as follows:

[0013] 1) Risk level classification: Multiple risk levels are classified based on the wear value of the wire rope;

[0014] 2) Set the initial position of the leakage magnetic field sensor installed on the wire rope monitored by each hoisting equipment, which is the reference point;

[0015] 3) Collect data from the magnetic flux leakage sensors installed on all hoisting equipment in the beam yard;

[0016] 4) Upload the collected data to the TST flaw detection equipment cloud platform;

[0017] 5) The data processing module is used to extract data from the TST flaw detection equipment cloud platform for preprocessing;

[0018] 6) Compare and analyze the preprocessed data to determine whether the data exceeds the alarm threshold. If it does, the TST flaw detection equipment cloud platform will issue an alarm and classify the data into the corresponding alarm risk level. The location information of the wire rope will be tracked, and the risk level and location information of the damaged wire rope will be automatically displayed in a pop-up window. The risk level and location information of the damaged wire rope will also be stored in the damaged wire rope risk level and location information.

[0019] 7) Verify and process the wire rope according to the risk level and location information;

[0020] 8) After verifying that the wire rope is correct, replace it accordingly.

[0021] Furthermore, the risk level and location information of the damaged wire rope in step 6) above are read through a mobile APP, and the alarm information is uploaded to the management personnel and on-site personnel. After verification, the management personnel and on-site personnel take corresponding actions.

[0022] Furthermore, after verifying that the above step 8) is correct, it also includes changing the hoisting site to reposition and hoist the box girder.

[0023] The beneficial effects of this invention are as follows: Compared with the prior art, this invention magnetizes the wire rope with a magnetizing body and uses leakage magnetic flux sensors arranged at intervals with the magnetizing body to detect magnetic flux. If a sudden change in data occurs and exceeds a set threshold, an early warning is issued. This allows for full-process monitoring and early warning of the wire ropes of numerous heavy hoisting equipment in beam yards, improving safety, reducing the probability of accidents, achieving intelligent operation, and improving production efficiency. The spaced installation of the magnetizing body and leakage magnetic flux sensors avoids the influence of the strong magnetic field of the magnetizing body on the detection of the leakage magnetic flux sensors, improving detection accuracy. The wire rope monitoring system enables intelligent monitoring throughout the entire process, allowing for real-time online data reading and intelligent monitoring and early warning throughout the entire life cycle of the wire rope. Attached Figure Description

[0024] Fig. 1 A schematic diagram of the mounting structure of the magnetizer and the leakage magnetic field sensor;

[0025] Fig. 2 This is a diagram illustrating the connection of the monitoring system;

[0026] Fig. 3 A schematic diagram of the intelligent monitoring method for steel wire ropes of large hoisting equipment in high-speed railway box girder prefabrication yards. Detailed Implementation

[0027] The invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0028] Example 1: Refer to Figs. 1-3 As shown, an intelligent monitoring system for steel wire ropes of large hoisting equipment in a high-speed railway beam yard includes a magnetizer 1, a magnetic flux leakage sensor 2, a data acquisition terminal 3, and an information platform 4. The magnetizer 1 and the magnetic flux leakage sensor 2 are installed alternately on the top mounting beam 5, and the U-shaped openings of both the magnetizer 1 and the magnetic flux leakage sensor 2 can pass through the vertical section of the 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 equipped with a steel wire rope monitoring system, which includes a data processing module, a data analysis and comparison module, and a data alarm and reminder module. The data processing module is used to preprocess the data collected by the magnetic flux leakage sensor. The data analysis and comparison module is used to compare the collected data with a set threshold to determine whether the data error meets the requirements. The alarm and reminder module is used to issue an alarm and reminder for data exceeding the set threshold.

[0029] A magnetizer and a sensor are installed on each wire rope of the large hoisting equipment. Both monitoring instruments are small in size and have no strict requirements for the installation environment, making installation convenient. The back of both the magnetizer and sensor housings has φ9mm, 20mm deep threaded mounting holes. Simply ensure there is a mounting plate at a set distance from the center of the wire rope to be inspected. During installation, to meet the spacing requirements of the sensor and magnetizer, and the spacing of the mounting holes on their respective housings, drill φ9mm through holes in the steel plate and fix the magnetizer and sensor with M8 screws of appropriate length through the steel plate. During installation, the N and S polarities of the magnetizer and sensor must be aligned along the direction of the wire rope.

[0030] To improve detection accuracy and avoid large errors in detection data caused by shaking, dual positioning guide wheels 6 are installed on the steel wire rope segments on both sides of the magnetizer 1 and both sides of the leakage magnetic sensor 2. The dual 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 staggered 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 hoisting equipment. The two pairs of first guide wheels 601 and second guide wheels 602 can make the steel wire rope of the magnetizer 1 form a squeezed and taut state.

[0031] To prevent the formation of a large, strong magnetic field due to the winding of the magnetized wire rope from affecting the normal operation of electronic devices, an intelligent monitoring system for wire ropes of large hoisting equipment in a high-speed railway beam yard includes two demagnetizers 7. The two demagnetizers 7 are installed on the top mounting beam 5 and are located between the magnetizer 1 and the wire rope lifting device, and between the leakage magnetic sensor 2 and the wire rope winding drum, respectively. By installing the demagnetizers, the wire rope after leakage magnetic detection is demagnetized, preventing it from winding on the wire rope winding drum and forming a large magnetic field. It can also demagnetize the wire rope after it passes through the magnetizer during the lowering of the lifting device. After overall demagnetization, dust on site is also prevented from adhering to the wire rope, thus improving the stability of the wire rope in use.

[0032] To improve the detection stability of the magnetic flux leakage sensor, the aforementioned magnetic flux leakage sensor 2 is connected to the top mounting beam 5 via 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 both 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 is connected to the top mounting beam 5 via a shock-absorbing rubber pad 805. A partition cavity is provided inside the cantilever shock-absorbing box 802, and shock-absorbing steel balls of different sizes are placed inside the partition cavity. Through the cantilever shock-absorbing box, a better damping effect can be provided, greatly reducing the vibration amplitude and achieving a better shock absorption effect. Combined with the shock-absorbing rubber pads and shock-absorbing rubber at both ends, it can achieve a multi-directional shock absorption effect, further improving the detection stability and detection accuracy of the magnetic flux leakage sensor.

[0033] To facilitate data use and rapid retrieval, a smart monitoring system for steel wire ropes of large hoisting equipment in high-speed railway beam yards also includes a TST flaw detection equipment cloud platform 9. The data acquisition terminal 3 is connected to the TST flaw detection equipment cloud platform 9, and the data collected by the acquisition terminal is quickly uploaded through an IoT card to improve efficiency and data processing efficiency. The TST flaw detection equipment cloud platform 9 is connected to an information platform 4.

[0034] To accurately locate and detect damage, a smart monitoring system for wire ropes in large hoisting equipment at high-speed railway beam yards also includes a wire rope release length measuring device and a position marking module. The wire rope release length measuring device measures the released length of the wire rope and is connected to a data acquisition terminal 3. The position marking module marks the distance of the damage location relative to a reference point during non-destructive testing. By measuring the length, the system can accurately detect the distance change relative to the reference point, thus precisely identifying the damage location. The position marking module automatically marks this location information. The information noted includes the hoisting equipment serial number, the specific wire rope to be monitored for that hoisting application serial number, the location and magnitude of the damage, the alarm level, and the monitoring time. This information allows for quick and timely identification of the equipment and location of the damaged wire rope, facilitating prompt notification to the relevant equipment management personnel for handling, thus improving processing efficiency, hoisting efficiency, and the efficiency of site transitions. The wire rope release length measuring device uses a rotary encoder. The rotary encoder is mounted on the positioning guide wheel frame via a fixed bracket, and its rotation axis is aligned with the axle of one of the guide wheels. By measuring the number of rotations, the distance is converted into a linear distance, thereby achieving length measurement.

[0035] To facilitate management, a smart monitoring system for wire ropes of large hoisting equipment in high-speed railway beam yards also includes a mobile APP 10. The mobile APP 10 is connected to the TST flaw detection equipment cloud platform 9. Project management personnel all have a real-name authenticated mobile APP account. The mobile APP software synchronizes data with the beam yard information platform. The mobile APP software can also display the equipment list, wire rope assessment overview, and monitoring details of each wire rope. When the wear value of the wire rope exceeds the set alarm threshold, the alarm information will be pushed to the relevant management personnel in real time through the mobile APP software. Management personnel can grasp the wear status of the wire ropes immediately, promptly inspect and replace the wire ropes, eliminate safety hazards, and ensure construction safety.

[0036] Working Principle: The leakage magnetic field generated by surface breakage in steel wire ropes, or the abrupt changes in localized magnetic fields due to internal damage and excessive fatigue, represents or reflects various damages and material failures in the components. This abnormal information is extracted using full magnetic technology, filtered and analyzed using correct identification patterns and mathematical models, and magnetized by magnetizing bodies installed on the wire rope to transform the chaotic magnetic field signals inside the rope into a uniform and detectable magnetic field. Sensors installed on the wire rope then collect wear data in real time, enabling quantitative flaw detection of ferromagnetic components. The digital signal containing the wire rope damage information is transmitted to the beam yard information platform for effective monitoring via the platform and a mobile app.

[0037] Example 2: A monitoring method for an intelligent monitoring system of wire ropes for large hoisting equipment in high-speed railway beam yards, the method is as follows:

[0038] 1) Risk level classification: Multiple risk levels are classified based on the wear value of the wire rope;

[0039] 2) Set the initial position of the leakage magnetic field sensor installed on the wire rope monitored by each hoisting equipment, which is the reference point;

[0040] 3) Collect data from the magnetic flux leakage sensors installed on all hoisting equipment in the beam yard;

[0041] 4) Upload the collected data to the TST flaw detection equipment cloud platform;

[0042] 5) The data processing module is used to extract data from the TST flaw detection equipment cloud platform for preprocessing;

[0043] 6) Compare and analyze the preprocessed data to determine whether the data exceeds the alarm threshold. If it does, the TST flaw detection equipment cloud platform will issue an alarm and classify the data into the corresponding alarm risk level. The location information of the wire rope will be tracked, and the risk level and location information of the damaged wire rope will be automatically displayed in a pop-up window. The risk level and location information of the damaged wire rope will also be stored in the damaged wire rope risk level and location information.

[0044] 7) Verify and process the wire rope according to the risk level and location information;

[0045] 8) After verifying that the wire rope is correct, replace it accordingly.

[0046] In step 6), the risk level and location information of the damaged wire rope are read through the mobile APP, and the alarm information is uploaded to the management personnel and on-site personnel. After verification, the management personnel and on-site personnel take appropriate action.

[0047] After verifying that the steps in step 8 are correct, the process also includes changing the hoisting site to reposition and hoist the box girder.

[0048] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of protection of the claims.

Claims

1. A high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system, characterized in that: The utility model relates to a kind of steel wire rope monitoring system, including magnetized body (1), magnetic flux leakage sensor (2), data acquisition terminal (3) and information platform (4), magnetized body (1) and magnetic flux leakage sensor (2) are installed at the vertical section of top mounting beam (5) and can pass through steel wire rope (11), magnetic flux leakage sensor (2) is connected to data acquisition terminal (3), data acquisition terminal (3) is connected to information platform (4), information platform (4) is provided with steel wire rope monitoring system, steel wire rope monitoring system is provided with data processing module, data analysis comparison module and data alarm reminding module, data processing module is used to pre-process the data collected by magnetic flux leakage sensor, data analysis comparison module is used to compare the data collected with set threshold, to judge whether data error size meets requirements, alarm reminding module is used to alarm and remind data exceeding set threshold. Magnetized body (1) both sides and magnetic flux leakage sensor (2) both sides corresponding steel wire rope section are equipped with double-positioning guide wheel (6), double-positioning guide wheel (6) includes first guide wheel (601) and second guide wheel (602), first guide wheel (601) and second guide wheel (602) are staggered and rotationally connected on positioning guide wheel frame (603), positioning guide wheel frame (603) is fixedly connected on the top mounting beam (5) of hoisting equipment, two pairs of first guide wheel (601) and second guide wheel (602) can make magnetized body (1) out of steel wire rope form extrusion straightening state;It also includes two demagnetizers (7), two demagnetizers (7) are installed on top mounting beam (5) and are located between magnetized body (1) and steel wire rope sling and between magnetic flux leakage sensor (2) and steel wire winding drum respectively; Magnetic flux leakage sensor (2) is connected in top mounting beam (5) by damping frame (8), damping frame (8) includes fixed plate (801), cantilever damping box (802) and mounting plate (803), fixed plate (801) and mounting plate (803) are fixedly connected on both ends of cantilever damping box (802) in I shape, damping rubber pad (804) is installed between fixed plate (801) and magnetic flux leakage sensor (2), mounting plate (803) and top mounting beam (5) are connected by damping rubber (805), and the cantilever damping box (802) is provided with a partition chamber, and the partition chamber is placed with damping steel balls of different sizes.

2. The high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system according to claim 1, characterized in that: It also includes TST flaw detection equipment cloud platform, data acquisition terminal (3) is connected to TST flaw detection equipment cloud platform, and TST flaw detection equipment cloud platform is connected to information platform.

3. The high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system according to claim 1, characterized in that: It also includes steel wire rope length measuring device and position marking module, steel wire rope length measuring device is used to measure steel wire rope length, and steel wire rope length measuring device is connected to data acquisition terminal (3), and position marking module is used to mark damage position of steel wire rope length in nondestructive testing process relative to reference point position, and damage mark is the distance of damage position relative to reference point.

4. The high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system according to claim 1, characterized in that: It also includes mobile phone APP end, and mobile phone AAP end is connected to TST flaw detection equipment cloud platform.

5. The monitoring method of the high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system according to claim 1, characterized in that: The method is as follows: 1) risk level division, according to steel wire rope wear value, multiple risk levels are divided; 2) Set the initial position of the magnetic flux leakage sensor installed by each hoisting equipment, which is the reference point; 3) Collect the data of the magnetic flux leakage sensor installed by 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 and preprocess the data in the TST flaw detection equipment cloud platform; 6) Compare and analyze the preprocessed data to determine whether the data is greater than the set threshold value of the alarm. If it is greater than the TST flaw detection equipment cloud platform, an alarm will be sounded, and the damaged steel wire rope risk level and position information will be classified into the corresponding alarm risk level, and the damaged steel wire rope risk level and position information will be tracked and automatically displayed in a pop-up window. The damaged steel wire rope risk level and position information will be stored in the damaged steel wire rope risk level and position information; 7) According to the risk level and position information, the steel wire rope is verified and processed; 8) After verification, the corresponding steel wire rope is replaced.

6. The monitoring method of the high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system according to claim 5, characterized in that: In step 6), the damaged steel wire rope risk level and position information are read through the mobile phone APP and the alarm information is uploaded to the management personnel and on-site personnel. After verification, the management personnel and on-site personnel handle the corresponding treatment.

7. The monitoring method of the high-speed rail beam field large hoisting equipment steel wire rope intelligent monitoring system according to claim 5, characterized in that: In step 8), after verification, the box girder is also replaced and hoisted in the hoisting yard.

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