Fault prediction and early warning device for crane transmission mechanism

Abstract

The invention relates to the field of large hoisting machinery construction, in particular to a crane transmission mechanism fault prediction and early warning device which comprises a box body and a probe, a cavity is formed in the box body, a vibration sensor, an analog-to-digital converter, a controller and a battery pack are fixedly installed in the cavity of the box body, and the vibration sensor is electrically connected with the probe through a telescopic connecting line. According to the device, by collecting vibration data of the transmission mechanism of the tower crane in real time and conducting analysis and prediction, potential fault hidden dangers can be found in time, an early warning signal is sent out through the early warning lamp, an operator is reminded to do maintenance work in time, and the safety of the tower crane is guaranteed. Therefore, potential safety hazards and economic losses caused by faults of the crane in the construction process are remarkably reduced, and the controller in the device can accurately judge the running state of the crane according to preset vibration threshold data and actually-collected digital signal vibration data.

Description

Technical Field

[0001] The invention relates to the field of large-scale lifting machinery construction, and in particular to a crane transmission mechanism fault prediction and early warning device. Background Art

[0002] In the field of large-scale special equipment construction, gantry cranes (also known as gantry cranes) and tower cranes (also known as tower cranes) have become indispensable key equipment in various construction projects due to their powerful cargo transportation capabilities. These two types of lifting machinery not only carry heavy logistics tasks, but also show extremely high application value in complex and changing working environments due to their characteristics of high-altitude operations. However, it is precisely because of the high complexity of their structures, the unpredictability of the working environment, and the stringent requirements of bearing heavy and variable loads for a long time that gantry cranes and tower cranes face many challenges during use, especially the safety hazards caused by frequent failures.

[0003] High security risk background

[0004] The working characteristics of gantry cranes and tower cranes determine that they must operate at high altitudes, over a large area, and often under adverse weather conditions, which not only increases the difficulty of operation, but also greatly increases safety risks. Especially at construction sites, these two types of equipment have a large lifting height and a wide operating coverage. Once a failure occurs, the consequences will be disastrous, which may not only cause equipment damage, but also endanger the lives of personnel, causing immeasurable economic losses and social impacts.

[0005] Frequent failures

[0006] Due to the complexity of the structure of gantry cranes and tower cranes and the harsh working environment, they are prone to various faults during use. Wear of mechanical parts, failure of electrical systems, abnormalities of transmission mechanisms, etc. are all common types of faults. These faults will not only affect the normal operation of the equipment, but may also cause abnormal vibration of the equipment, thereby threatening the stability and safety of the entire lifting system. Especially under heavy load or variable load conditions, the probability of failure increases significantly, bringing great uncertainty to construction safety.

[0007] Limitations of existing solutions

[0008] Although there are some technologies and methods for crane vibration monitoring, they still have obvious shortcomings in practical applications:

[0009] Low monitoring accuracy: Traditional monitoring methods are limited by technical level and equipment performance, and often cannot provide sufficiently high data resolution, making it difficult to accurately capture and identify the subtle abnormal vibration signals generated during the operation of the crane. This results in many potential faults not being discovered and handled in a timely manner, thereby increasing safety risks.

[0010] Early warning is not timely: the existing monitoring system often has a slow response speed and cannot quickly issue effective early warning signals at the early stage of a fault. This results in the best time to deal with the fault being missed, which may further develop into a more serious safety problem. Summary of the invention

[0011] 1. Technical issues to be solved

[0012] In view of the deficiencies in the prior art, the present invention provides a crane transmission mechanism fault prediction and early warning device.

[0013] (II) Technical solution

[0014] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: A crane transmission mechanism fault prediction and warning device of the present invention comprises a box body and a probe, a cavity is provided inside the box body, a vibration sensor, an analog-to-digital converter, a controller and a battery pack are fixedly installed in the cavity of the box body, the vibration sensor is electrically connected to the probe through a telescopic connecting line, an access port is provided at the upper part of the box body, the telescopic connecting line passes through the access port, the vibration sensor is electrically connected to the analog-to-digital converter, the analog-to-digital converter is electrically connected to the controller, a control switch and a charging port are provided on the box body, the control switch and the charging port are electrically connected to the battery pack in the cavity of the box body, and the controller is electrically connected to the control switch.

[0015] Preferably, a warning light is provided on the upper portion of the box, a controller and a battery pack are installed inside the box, and the warning light is electrically connected to the controller inside the box for transmitting warning information.

[0016] Further preferably, the battery pack includes a plurality of storage batteries, and the plurality of storage batteries are connected in parallel.

[0017] Again preferably, a fixing piece is installed on the box body, and the fixing piece is arranged on the left side of the box body, and a plurality of mounting holes are arranged around the side of the fixing piece.

[0018] Preferably, a protective shell is installed on the inlet, and the protective shell is wrapped around the outside of the telescopic connecting line.

[0019] Further preferably, the warning light adopts a high-brightness LED light.

[0020] Again preferably, the protective shell is made of high-strength wear-resistant material, and the high-strength wear-resistant material includes any one of metal material, polymer material, carbon fiber reinforced plastic and metal-based composite material.

[0021] Preferably, the controller is provided with a power detection system and a low power alarm function, the control switch is provided with an indicator light, and the low power alarm function is adapted to the indicator light.

[0022] Further preferably, the fixing part is welded to the box body, and the fixing part is made of Q235 steel plate.

[0023] (III) Beneficial effects

[0024] Compared with the prior art, the present invention provides a crane transmission mechanism fault prediction and early warning device, which has the following beneficial effects:

[0025] Improved safety and reliability:

[0026] The device collects vibration data of the tower crane's transmission mechanism in real time and performs analysis and prediction. It can promptly detect potential fault hazards and send out warning signals through warning lights to remind operators to perform maintenance work in a timely manner, thereby significantly reducing safety hazards and economic losses caused by crane failures during construction.

[0027] Enhance the timeliness and pertinence of equipment maintenance:

[0028] The controller in the device can accurately determine the operating status of the crane based on the preset vibration threshold data and the actual collected digital signal vibration data. When the vibration data is abnormal, an early warning is triggered immediately, allowing maintenance personnel to respond quickly and conduct targeted inspections and repairs on the equipment, thereby improving maintenance efficiency.

[0029] Extend equipment life:

[0030] Through regular monitoring and early warning, minor faults in the crane's transmission mechanism can be discovered and dealt with in a timely manner to prevent the fault from expanding and causing equipment damage, thereby effectively extending the crane's service life and reducing equipment replacement costs.

[0031] Improve battery pack performance and power supply stability:

[0032] The battery pack adopts a parallel structure to improve the total capacity and power supply stability. Even if a single battery has a problem, the other batteries can continue to supply power, ensuring the continuous operation of the system and reducing equipment downtime caused by insufficient power.

[0033] Excellent protection and durability:

[0034] Key parts of the device, such as the retractable connecting wires passing through the box body, are equipped with protective shells made of high-strength wear-resistant materials to effectively protect the internal connecting wires from damage. At the same time, the fixings are made of Q235 steel plates and welded to ensure that the entire device can remain stable in harsh environments and improve the durability of the device.

[0035] Significant early warning effect:

[0036] The warning light uses a high-brightness LED light that is clearly visible both during the day and at night, ensuring that operators can notice abnormal situations in time and take appropriate measures to avoid accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of the external structure of the box of the present invention;

[0038] Figure 2 It is a schematic diagram of the cross-sectional structure of the box body of the present invention;

[0039] In the figure: 1. Box; 1-1. Vibration sensor; 1-2. Analog-to-digital converter; 1-3. Controller; 1-4. Battery pack; 1-5. Access port; 2. Probe; 3. Telescopic connecting wire; 4. Protective shell; 5. Fixing part; 6. Control switch; 7. Charging port; 8. Warning light. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] See also Figure 1-2 A crane transmission mechanism fault prediction and warning device of the present invention comprises a box body 1 and a probe 2. A cavity is provided inside the box body 1. A vibration sensor 1-1, an analog-to-digital converter 1-2, a controller 1-3 and a battery pack 1-4 are fixedly installed in the cavity of the box body 1. A telescopic connecting line 3 is provided on the vibration sensor 1-1. The sensor 1-1 is electrically connected to the probe 2 through the telescopic connecting line 3. An access port 1-5 is provided on the upper part of the box body 1. The telescopic connecting line 3 passes through the access port 1-5. The vibration sensor 1-1 is electrically connected to the analog-to-digital converter 1-2. The analog-to-digital converter 1-2 is electrically connected to the controller 1-3. A control switch 6 and a charging port 7 are provided on the box body 1. The control switch 6 and the charging port 7 are electrically connected to the battery pack 1-4 in the cavity of the box body 1. The controller 1-3 is electrically connected to the control switch.

[0042] The crane transmission mechanism fault prediction and early warning device is designed to monitor the operating status of the crane transmission mechanism in real time by integrating multiple sensors and controllers, and issue early warning signals when abnormal conditions are detected. The following is its detailed working principle:

[0043] Vibration data collection:

[0044] Probe 2: Installed at the key position of the crane transmission mechanism, used to collect vibration data in real time.

[0045] Telescopic connecting wire: electrically connects the probe to the vibration sensor 1-1 in the box to ensure the flexibility and stability of data transmission.

[0046] The left end of the telescopic connecting line 3 is connected to the vibration sensor 1-1 through the inlet 1-5 at the upper end of the box 1, and the right end of the telescopic connecting line 3 is connected to the probe 2; the telescopic connecting line 3 is wrapped and protected by a protective shell 4 at the inlet 1-5 passing through the box 1, and the connection between the inlet 1-5 and the telescopic connecting line 3 can be sealed by a rubber sealing gasket.

[0047] Protective shell 4: Wrapped around the outside of the telescopic connecting wire 3, it is made of high-strength wear-resistant material to protect the connecting wire from the external environment.

[0048] Data processing and analysis:

[0049] Vibration sensor 1-1: receives vibration data collected by probe 2 and outputs analog signals.

[0050] Analog-to-digital converter 1-2: converts the analog signal output by the vibration sensor 1-1 into a digital signal for subsequent processing.

[0051] Controller 1-3: Determines whether the operation status of the crane transmission mechanism is normal based on the preset vibration threshold and the input digital signal. If abnormal vibration is detected, controller 1-3 will trigger the early warning mechanism;

[0052] Carry out maintenance work in a timely manner to reduce safety hazards and economic losses caused by crane failures during construction.

[0053] Early warning information transmission:

[0054] Warning light 8: It uses a high-brightness LED light. When the controller 1-3 detects an abnormality, it controls the warning light 8 to emit an obvious light signal to remind the operator to pay attention to safety.

[0055] Power detection system: monitors the power status of the battery pack. When the power is low, the indicator light on the control switch 6 will send a low power alarm to remind the user to charge in time.

[0056] Power Management:

[0057] Battery pack 1-4: consists of several batteries connected in parallel to provide stable power support. The battery pack is charged through the charging port 7 to ensure long-term stable operation of the device.

[0058] Fixing and installation:

[0059] Fixing part 5: It is set on the left side of the box body 1, and is made of Q235 steel plate and fixed to the box body 1 by welding to ensure that the device is firm and reliable. There are multiple mounting holes on the side of the fixing part 5 for easy installation and removal.

[0060] In this embodiment, the specific connection methods of various parts all adopt conventional means such as mature bolts, rivets, welding, etc. in the prior art. The machinery, parts and equipment all adopt conventional models in the prior art. The circuit connection adopts the conventional connection method in the prior art, which will not be described in detail here.

[0061] The detailed working principle is as follows:

[0062] First, when using the device, first install the device on the tower crane transmission mechanism through the fixing member 5, and turn on the control switch 6 to power the device;

[0063] Second, when using this device to monitor the vibration during the construction of the tower crane transmission mechanism, fix the probe 2 to the component of the monitoring part of the tower crane transmission mechanism, and check whether the control switch 6 is turned on. The vibration amplitude sensed by the probe 2 will be transmitted to the box 1 through the retractable connecting line 3. According to the current vibration level, check whether the warning light 8 is warning, so as to determine whether the equipment needs maintenance.

[0064] Working principles of each preferred technical solution

[0065] Battery Pack 1-4 Design:

[0066] Parallel structure: Several batteries are connected in parallel, which improves the total capacity and power supply stability of battery packs 1-4. Even if a single battery has a problem, the other batteries can continue to supply power to ensure the continuous operation of the system.

[0067] Protective shell 4 material selection:

[0068] High-strength wear-resistant material: Select one of metal materials, polymer materials, carbon fiber reinforced plastics or metal-based composite materials. These materials have good impact resistance and wear resistance, and can effectively protect the internal connecting wires from damage.

[0069] Warning light 8 configuration:

[0070] High-brightness LED light: High-brightness LED light is used as the warning light 8, which can be clearly seen during the day or at night, significantly improving the warning effect and ensuring that the operator notices abnormal conditions in time.

[0071] Battery detection and low battery alarm:

[0072] Power detection system: Built-in intelligent algorithm to monitor the power level of the battery pack in real time. The power detection system can be configured with a mature power meter product to measure the power level of the battery pack.

[0073] Low battery alarm function: When the battery level is lower than the preset threshold, the alarm is automatically triggered, and the indicator light on the control switch 6 flashes to warn the user to charge in time to prevent the device from shutting down due to insufficient power.

[0074] Fixing 5 Design:

[0075] Q235 steel plate: Q235 steel plate is selected as the fixing material, which has high strength and corrosion resistance and is suitable for long-term use in industrial environments.

[0076] Welding fixation: The fixing member 5 is firmly mounted on the box body 1 by welding, ensuring that the entire device can remain stable even in harsh environments.

[0077] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A crane transmission mechanism fault prediction and early warning device, characterized in that: The invention comprises a box (1) and a probe (2), wherein a cavity is provided inside the box, and a vibration sensor (1-1), an analog-to-digital converter (1-2), a controller (1-3) and a battery pack (1-4) are fixedly installed in the cavity of the box, wherein the vibration sensor (1-1) is electrically connected to the probe (2) via a telescopic connecting line (3), an access port (1-5) is provided at the top of the box (1), and the telescopic connecting line (3) passes through the access port (1-5), the vibration sensor (1-1) is electrically connected to the analog-to-digital converter (1-2), and the analog-to-digital converter (1-2) is electrically connected to the controller (1-3), and a control switch (6) and a charging port (7) are provided on the box (1), wherein the control switch (6) and the charging port (7) are electrically connected to the battery pack (1-4) in the cavity of the box (1), and the controller (1-3) is electrically connected to the control switch (6).

2. A crane transmission mechanism fault prediction and early warning device according to claim 1, characterized in that: A warning light (8) is provided on the upper part of the box (1), a controller (1-3) and a battery pack (1-4) are installed inside the box (1), and the warning light (8) is electrically connected to the controller (1-3) inside the box (1) for transmitting warning information.

3. A crane transmission mechanism fault prediction and early warning device according to claim 2, characterized in that: The battery pack (1-4) comprises a plurality of storage batteries, and the plurality of storage batteries are connected in parallel.

4. A crane transmission mechanism fault prediction and early warning device according to claim 3, characterized in that: A fixing member (5) is installed on the box body (1), and the fixing member (5) is arranged on the left side of the box body (1). A plurality of mounting holes are arranged around the side of the fixing member (5).

5. A crane transmission mechanism fault prediction and early warning device according to claim 4, characterized in that: A protective shell (4) is installed on the inlet (1-5), and the protective shell (4) is wrapped around the outside of the telescopic connecting line (3).

6. A crane transmission mechanism fault prediction and early warning device according to claim 5, characterized in that: The warning light (8) is a high-brightness LED light.

7. A crane transmission mechanism fault prediction and early warning device according to claim 6, characterized in that: The protective shell (4) is made of high-strength wear-resistant material, and the high-strength wear-resistant material includes any one of metal material, polymer material, carbon fiber reinforced plastic and metal-based composite material.

8. A crane transmission mechanism fault prediction and early warning device according to claim 7, characterized in that: The controller (1-3) is equipped with a power detection system and a low power alarm function, and the control switch (6) is provided with an indicator light, and the low power alarm function is adapted to the indicator light.

9. A crane transmission mechanism fault prediction and early warning device according to claim 8, characterized in that: The fixing part (5) is welded to the box body (1), and the fixing part (5) is made of Q235 steel plate.

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