Early warning device and early warning method for service life of power catwalk steel wire rope

Abstract

The invention discloses a life early warning device for a power catwalk steel wire rope. A tension sensor and a roller encoder are connected with a controller through signal lines respectively; and the controller is respectively connected with an alarm and a reset button through signal lines. The invention further discloses a life early warning method for the power catwalk steel wire rope, which comprises the following steps of: 1, collecting the tension of the steel wire rope, and calculating to obtain the tension stress of the steel wire rope; 2, the rotation angle of a roller is collected, and the walking distance of a drill string is obtained through calculation; 3, the controller 3 calculates the loss value of the steel wire rope per ton kilometer in the power catwalk; 4, the controller evaluates the service life of the steel wire rope and gives an alarm according to conditions; and 5, replacing a new steel wire rope according to conditions, and restarting a new cycle. According to the device and method, the service life of the power catwalk steel wire rope is quantitatively evaluated, and the defect that equipment is wasted or the operation risk of the catwalk is increased due to the fact that the steel wire rope cannot be replaced on schedule due to human reasons is avoided.

Description

Technical Field

[0001] The invention belongs to the technical field of automatic control, and relates to a life warning device for a steel wire rope of a power catwalk. The invention also relates to a life warning method for a steel wire rope of a power catwalk. Background Art

[0002] DM4.5-15-4LDY power catwalk is a newly emerged wire rope lifting power catwalk with large tonnage, long distance and multiple single pipe conveying capabilities. One end of the wire rope is fixed on the drum, and the other end is fixed on the drill string of the power catwalk. The drum is driven by a motor to rotate and drive the drill string up and down. It is widely used in automated drilling rigs due to its high efficiency, simple structure and easy use.

[0003] As the link of power transmission of power catwalk, the service life of wire rope is the focus of users' attention. The service life of wire rope is affected by many factors such as material, environment, load, maintenance, etc. At present, the life detection of wire rope of power catwalk is mainly carried out through regular inspection, observation, recording and other means, which makes the subjective factors of inspectors large and the operation difficult, and is prone to problems such as missed inspection, inaccurate or missing records. In particular, the inspection method relying on inspectors cannot quantitatively give the use of wire rope, which may lead to waste due to premature replacement of wire rope, or increase the operation risk of power catwalk due to late replacement of wire rope.

[0004] Therefore, a more scientific method is urgently needed to analyze the service life of the power catwalk wire rope, so as to replace the wire rope in time with more accurate evaluation standards and achieve the rational use of the equipment. Summary of the invention

[0005] The purpose of the present invention is to provide a life warning device for a wire rope of a power catwalk, which solves the problem that the prior art lacks a scientific wire rope life assessment standard for wire rope lifting power catwalks, resulting in difficulty in accurately warning the wire rope life.

[0006] Another object of the present invention is to provide a life warning method for a power catwalk wire rope, which can more accurately evaluate the service life of the wire rope, achieve rational utilization of the equipment, and avoid the operation risks of the power catwalk.

[0007] The technical solution adopted by the present invention is a life warning device for a power catwalk wire rope, including a tension sensor and a roller encoder, the tension sensor and the roller encoder are respectively connected to a controller through a signal line; the controller is respectively connected to an alarm and a reset button through the signal lines.

[0008] Another technical solution adopted by the present invention is a life warning method for a power catwalk steel wire rope, which is implemented by using the life warning device for the power catwalk steel wire rope according to the following steps:

[0009] Step 1, collect the wire rope tension and calculate the tensile stress of the wire rope;

[0010] Step 2: Collect the rotation angle of the drum and calculate the travel distance of the drill string;

[0011] Step 3, the controller 3 calculates the ton-kilometer loss value of the wire rope in the power catwalk;

[0012] Step 4: The controller evaluates the service life of the wire rope and issues an alarm as needed;

[0013] Step 5: Replace the wire rope as needed and start the cycle again.

[0014] The beneficial effect of the present invention is that the wire rope life warning device and warning method based on the DM4.5-15-4LDY power catwalk solves the problem that the service life of the power catwalk wire rope cannot be quantitatively evaluated by using tension sensors, roller encoders, controllers, alarms, reset buttons, and utilizing automatic control technology, thereby avoiding the disadvantages of not being able to replace the wire rope on time due to human reasons, thereby causing equipment waste or increasing the risk of catwalk operation. It can not only reduce the labor intensity of maintenance personnel, but also provide key technical support for the rational procurement of equipment by drilling companies. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the structure of the life warning device for the wire rope of the power catwalk;

[0016] Figure 2 It is a flow chart of the life warning method of the wire rope of the power catwalk.

[0017] In the figure, 1. tension sensor, 2. roller encoder, 3. controller, 4. alarm, 5. reset button. DETAILED DESCRIPTION

[0018] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0019] Reference Figure 1 The structure of the wire rope life warning device of the present invention includes a tension sensor 1 and a drum encoder 2, the tension sensor 1 and the drum encoder 2 are respectively connected to a controller 3 through a signal line; the controller 3 is respectively connected to an alarm 4 and a reset button 5 through the signal lines.

[0020] The tension sensor 1 is arranged in front of the catwalk pulley to collect the tension of the wire rope.

[0021] The drum encoder 2 is arranged at the end of the central axis of the drum and is used to collect the rotation angle of the drum.

[0022] The controller 3 is responsible for information processing, and is used to receive and process the signal of the tension sensor 1, receive and process the signal of the roller encoder 2, receive the signal of the reset button 5, load all the operation programs involved in the early warning method, and control the alarm 4 to sound an alarm.

[0023] The reset button 5 includes a hardware physical button or a virtual button (touch button) on the operation screen. The reset button 5 can be used to reset the total ton-kilometers of the power catwalk wire rope operation.

[0024] The alarm device 4 includes a driller operation panel, a catwalk remote control box, and a voice alarm device, which are respectively connected to the signal output end of the controller 3 through signal lines.

[0025] The working principle of the device of the present invention is: using a tension sensor and a drum encoder to measure the wire rope tension and the drum rotation angle, and then completing the wire rope service life evaluation through a controller loaded with a wire rope early warning method calculation program. The dangerous evaluation result is output through an alarm. When a new wire rope is used for the first time, a reset button is used to clear the calculation data of the old wire rope to avoid false alarms.

[0026] Reference Figure 2 The wire rope life warning method of the present invention utilizes the aforementioned wire rope life warning device and is based on the DM4.5-15-4LDY power catwalk and is implemented according to the following steps:

[0027] For new wire ropes, the basic conditions are: the wire rope is intact, without extrusion, wire breakage, cracks and other damage.

[0028] Step 1: Collect the wire rope tension and calculate the tensile stress of the wire rope.

[0029] The tension sensor 1 is used to measure the tension of the steel wire rope in the power catwalk, and the measurement data of the tension sensor 1 is transmitted to the controller 3. The controller 3 calculates the tensile stress of the steel wire rope through a pre-stored program. The tensile stress expression of the steel wire rope is:

[0030] σ f =4mf / πkd 2 ,

[0031] Among them, m is the slope parameter, which is a constant related to the material, stress ratio, manufacturing process, etc.; f is the load tension on the wire rope; k is the filling coefficient of the wire rope; d is the outer diameter of the wire rope.

[0032] Step 2: Collect the rotation angle of the drum and calculate the travel distance of the drill string.

[0033] The drum encoder 2 is used to measure the drum rotation angle. The drum encoder 2 transmits the measured drum rotation angle to the controller 3. The controller 3 calculates the travel distance of the drill string through a pre-stored program. The expression of the travel distance is: l = πrΔθ / 180,

[0034] Among them, r is the approximate drum rotation radius of the current layer where the wire rope is located, and Δθ is the angle of rotation of the drum this time.

[0035] Step 3, the controller 3 calculates the ton-kilometer loss value of the wire rope in the power catwalk;

[0036] The controller 3 calculates the ton-kilometer loss of the power catwalk wire rope through a pre-stored program. The calculation process is:

[0037] During the operation of the power catwalk to deliver the drill string, the tensile stress of the wire rope σ f Perform distance statistics and assume that the stress amplitude σ i The action distance is s i , the ton-kilometers generated are D i =σ i s i , then the total ton-kilometer loss is the sum of the ton-kilometer losses of each level of stress amplitude, that is, D = ΣD i .

[0038] Step 4: The controller evaluates the service life of the wire rope and issues an alarm as appropriate.

[0039] The controller evaluates the service life of the wire rope through a pre-stored program. If the total ton-kilometer loss of the catwalk wire rope is greater than the maximum ton-kilometer of the wire rope, it is evaluated as dangerous, responds through the alarm 4 and then jumps to the next step;

[0040] Otherwise, the evaluation is normal and jump directly to step 5.

[0041] The maximum ton-kilometer value of a wire rope is the result obtained by the wire rope manufacturer through material fatigue load tests.

[0042] Step 5: Replace the wire rope as needed and start a new cycle.

[0043] If the equipment has replaced a new wire rope, the reset button 5 is used to reset the ton-kilometers to zero, and the controller 3 returns to step 1 through the pre-stored program to restart a new cycle; otherwise, it directly returns to step 1 to restart the cycle.

[0044] Example 1

[0045] The wire rope lifting type power catwalk early warning method proposed in this embodiment includes the following specific steps:

[0046] The basic conditions are as follows: the wire rope is intact, without any damage such as extrusion, wire breakage or cracks, and the wire rope is used for the first time.

[0047] Step 1: The tension of the power catwalk wire rope measured by tension sensor 1 is 180kN. The tension data is transmitted to the controller through the signal line, and the tensile stress of the wire rope is calculated to be 1.42kN / mm 2 ;

[0048] Step 2: The drum rotation angle measured by the drum encoder 2 is 1591.2°. The drum rotation angle is transmitted to the controller through the signal line, and the travel distance of the drill string is calculated to be 9437.6 mm.

[0049] Step 3: The controller 3 calculates the ton-kilometer loss value of the power catwalk wire rope as 0.00137 ton-kilometer;

[0050] Step 4: Evaluate the service life of the wire rope. Since the cumulative ton-kilometer loss value is less than the wire rope total ton-kilometer limit of 540, the alarm does not sound and jumps directly to step 5.

[0051] Step 5: Without replacing the new wire rope, go back to step 1 and restart the cycle.

[0052] Example 2

[0053] The wire rope lifting type power catwalk early warning method proposed in this embodiment includes the following specific steps:

[0054] The basic conditions are as follows: the wire rope is intact, without any damage such as extrusion, wire breakage or cracks. The cumulative ton-kilometer loss value before this operation was 539.999.

[0055] Step 1: The tension of the power catwalk wire rope measured by the tension sensor 1 is 210kN. The tension data is transmitted to the controller 3 through the signal line, and the tensile stress of the wire rope is calculated to be 1.66kN / mm 2 ;

[0056] Step 2: The drum rotation angle of 3762° is measured by the drum encoder 2, and the drum rotation angle is transmitted to the controller 3 through the signal line. The travel distance of the drill string is calculated to be 22312.84 mm;

[0057] Step 3: The controller 3 calculates the ton-kilometer loss value of the power catwalk wire rope to be 0.0038 ton-kilometer;

[0058] Step 4: Evaluate the service life of the wire rope. Since the accumulated ton-kilometer loss value is greater than the wire rope total ton-kilometer limit of 540, it is a dangerous state. The controller 3 outputs an alarm message to the alarm 4, and jumps to step 5 after the alarm.

[0059] Step 5: Maintenance personnel inspect the wire rope on site and confirm that the wire rope is used with caution. No new wire rope is replaced and the process returns to step 1 to restart the cycle.

[0060] Example 3

[0061] The wire rope lifting type power catwalk early warning method proposed in this embodiment includes the following specific steps:

[0062] The basic conditions are as follows: the wire rope is intact, without any damage such as extrusion, wire breakage or cracks, and the accumulated ton-kilometer loss value is greater than 540.

[0063] Step 1: The tension of the power catwalk wire rope measured by the tension sensor 1 is 0, the tension data is transmitted to the controller 3 through the signal line, and the tensile stress of the wire rope is calculated to be 0;

[0064] Step 2: The drum rotation angle measured by the drum encoder 2 is 0, and the drum rotation angle is transmitted to the controller 3 through the signal line, and the travel distance of the drill string is calculated to be 0;

[0065] Step 3: The controller 3 calculates that the ton-kilometer loss value of the power catwalk wire rope is 0;

[0066] Step 4: Evaluate the service life of the wire rope. Since the cumulative ton-kilometer loss value is greater than the wire rope total ton-kilometer limit of 540, alarm 4 outputs an alarm message and then jumps to step 5.

[0067] Step 5: On-site personnel confirm the replacement of the new wire rope. After the replacement of the new wire rope, use the reset button 5 to clear the ton-kilometer value used last time. The controller 3 returns to step 1 through the pre-stored program and restarts a new cycle.

Claims

1. A life warning device for a power catwalk wire rope, characterized in that: The invention comprises a tension sensor (1) and a roller encoder (2), wherein the tension sensor (1) and the roller encoder (2) are respectively connected to a controller (3) via a signal line; and the controller (3) is respectively connected to an alarm (4) and a reset button (5) via the signal line.

2. The life warning device for the power catwalk wire rope according to claim 1 is characterized in that: The tension sensor (1) is arranged in front of the catwalk pulley and is used to collect the tension of the wire rope.

3. The life warning device for the power catwalk wire rope according to claim 1 is characterized in that: The drum encoder (2) is arranged at the end of the central axis of the drum and is used to collect the rotation angle of the drum.

4. The life warning device for the power catwalk wire rope according to claim 1 is characterized in that: The controller (3) is responsible for information processing, and is used to receive and process signals from the tension sensor (1), receive and process signals from the roller encoder (2), receive signals from the reset button (5), load all operation programs involved in the early warning method, and control the alarm (4) to sound an alarm.

5. The life warning device for the steel wire rope of the power catwalk according to claim 1 is characterized in that: The reset button (5) comprises a hardware physical button or a virtual button on the operation screen, and the reset button (5) is used to reset the total ton-kilometers of the power catwalk wire rope operation.

6. A life warning method for a power catwalk steel wire rope, using the life warning device for a power catwalk steel wire rope according to any one of claims 1 to 5, characterized in that: Follow these steps to implement: Step 1, collect the wire rope tension and calculate the tensile stress of the wire rope; Step 2: Collect the rotation angle of the drum and calculate the travel distance of the drill string; Step 3, the controller (3) calculates the ton-kilometer loss value of the wire rope in the power catwalk; Step 4: The controller evaluates the service life of the wire rope and issues an alarm as needed; Step 5: Replace the wire rope as needed and start the cycle again.

7. The life warning method of the power catwalk wire rope according to claim 6 is characterized in that: In step 1, the specific process is: A tension sensor (1) is used to measure the tension of a steel wire rope in a power catwalk, and the measurement data of the tension sensor (1) is transmitted to a controller (3). The controller (3) calculates the tensile stress of the steel wire rope through a pre-stored program. The tensile stress of the steel wire rope is expressed as: s f =4mf / πkd 2 , Among them, m is the slope parameter; f is the load tension on the wire rope; k is the filling coefficient of the wire rope; d is the outer diameter of the wire rope.

8. The life warning method of the power catwalk wire rope according to claim 6 is characterized in that: In step 2, the specific process is: The drum encoder (2) is used to measure the drum rotation angle. The drum encoder (2) transmits the measured drum rotation angle to the controller (3). The controller (3) calculates the travel distance of the drill string through a pre-stored program. The expression of the travel distance is: l = πrΔθ180, Among them, r is the approximate drum rotation radius of the current layer where the wire rope is located, and Δθ is the angle of rotation of the drum this time.

9. The life warning method of the power catwalk wire rope according to claim 6 is characterized in that: In step 3, the specific process is: The controller (3) calculates the ton-kilometer loss of the power catwalk wire rope through a pre-stored program. The calculation process is: During the operation of the power catwalk to deliver the drill string, the tensile stress of the wire rope σ f Perform distance statistics and assume that the stress amplitude σ i The action distance is s i , the ton-kilometers generated are D i =σ i s i , then the total ton-kilometer loss is the sum of the ton-kilometer losses of each level of stress amplitude, that is, D = ΣD i .

10. The life warning method of the power catwalk wire rope according to claim 6, characterized in that: In step 4, the specific process is: The controller (3) evaluates the service life of the wire rope through a pre-stored program. If the total ton-kilometer loss of the catwalk wire rope is greater than the maximum ton-kilometer of the wire rope, it is evaluated as dangerous, responds through the alarm (4) and then jumps to the next step; Otherwise, the evaluation is normal and jump directly to step 5.

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