Detection device and detection method for main steel wire rope of ship unloader

Abstract

The invention relates to a ship unloader main steel wire rope detection device. The detection device comprises a stroke metering device, a weak magnetic detection device, a magnetic memory planning device, a guide wheel assembly, a steel wire rope, a hydraulic push rod and a control system. The weak magnetic detection device is arranged between the stroke metering device and the magnetic memory planning device, guide wheel assemblies are arranged on the two sides of the magnetic memory planning device, and the stroke metering device, the weak magnetic detection device, the magnetic memory planning device and the guide wheel assemblies are all fixedly installed on a cross rod connected with a hydraulic push rod. According to the technical scheme, existing mature technologies of mechanical transmission, electromagnetic induction, software automatic alarm and the like are fully utilized, intelligent control is taken as a target, and on the premise of economy, practicability, safety and reliability, the problems that the operation safety of the main steel wire rope of the port crane is poor and the control is not in place are solved; and the real-time performance and reliability of safe operation control of the main steel wire rope of the ship unloader are improved.

Description

Technical Field

[0001] The present invention relates to a detection device, in particular to a main wire rope detection device and a detection method for a ship unloader, belonging to the technical field of port logistics transportation. Background Art

[0002] The bridge grab ship unloader (ship unloader) in the raw material receiving center of the logistics department of Meigang Steel is a key equipment of the company. The main wire rope winding system is the core component of the bridge grab ship unloader. It consists of luffing wire ropes, hoisting wire ropes, opening and closing wire ropes, trolley traction wire ropes, and drums, pulleys, and idlers on each mechanism. Among them, the main wire ropes are the hoisting and opening and closing wire ropes, with a model of 6*36(WS)-IWRC-Φ40, and each is 260 meters long. Four wire ropes for hoisting, opening and closing, and trolley traction (triple combination) come out of the four drums for hoisting and opening and closing. After two of the wire ropes are redirected by the sea side upper crossbeam pulley group, the front girder sea side end redirecting pulley group, and the main trolley pulley group, they are respectively fixed on the grab; the other two wire ropes are redirected by the rear girder land side end redirecting pulley group and the main trolley pulley group and then fixed on the grab respectively. The ends of the four main wire ropes are cast pear-shaped sleeves, and are connected to the grab wire ropes by C-shaped rings.

[0003] The main wire ropes of the ship unloader are parts that frequently bear static and dynamic loads, and are key mechanisms when the ship unloader is working. During operation, it not only bears the static loads of the grab, materials, and its own weight, but also bears the dynamic loads caused by acceleration and impact. The wire ropes repeatedly wind around the drums and pulleys, periodically bearing large bending stresses and additional loads caused by bending; in addition, when the wire ropes are stressed and elongated, friction occurs between the wire ropes of the wire ropes, between the ropes and the pulley and the bottom of the drum groove, and between the ropes and the lifting parts. The wire ropes bear the resistance loads caused by friction. Under the action of these loads, the wire ropes generate large tensile and bending stresses. When the number of times of stretching and bending exceeds a certain value, the phenomenon of "metal fatigue" will occur in the wire ropes, and the wire ropes of the wire ropes will show wear and breakage after being used for a certain period of time. Therefore, the problems exposed by the main wire ropes of the ship unloader in production practice are mainly manifested as wear and wire breakage. The common forms of existing port crane wire rope detection schemes are as follows:

[0004] (1) During the wire rope inspection and maintenance process, the operator visually inspects the wire rope manually for possible appearance and mechanical damage, such as bending, wire breakage, extrusion of the wire rope core of a single strand, etc. Manual visual inspection is affected by factors such as incomplete observation, oil stain covering the wire rope, and lack of responsibility, which affect the detection effect.

[0005] (2) Comparing with the wire rope scrapping standard, the operator directly detects the wire rope manually using tools such as vernier calipers. This detection method has detection limitations, long detection time, some positions cannot be detected, serious missed detections, and high labor intensity.

[0006] (3) The operator holds a non-destructive testing device using electromagnetic principle to conduct non-destructive testing on the wire rope, which can detect various damages such as broken wires, wear, corrosion, and fatigue of the wire rope. However, it is powerless for the number of surface broken wires of the wire rope and the change in the wire rope diameter, etc., and cannot meet the technical requirements for comprehensive detection of the wire rope, and cannot provide a higher safety guarantee for wire rope detection.

[0007] When the hoisting and opening / closing wire ropes pass through the fixed pulleys on the river side and the land side and the fixed pulley of the main trolley, they are repeatedly bent, which is the key part most prone to fatigue broken wires and there is a hidden danger of wire rope breakage. At present, professional weekly inspections and daily inspections by the ship unloader driver are relied on to ensure the safety of special equipment operations. Manual inspections cannot detect the internal state of the main wire rope of the ship unloader. If effective safety monitoring means are not taken, wire rope breakage accidents are extremely likely to occur. The procurement cost of each main wire rope of the ship unloader is relatively high, the replacement cycle is long, and the required manpower and material resources are large. There is an urgent need to extend its service life through technological innovation and eliminate potential safety hazards.

[0008] We design a detection device integrating mechanical and electrical technologies, a wire rope automatic monitoring system, which integrates electromagnetic detection technology and AI artificial intelligence technology. It can not only automatically collect the information of the metal cross-sectional area loss remembered by the wire rope online in real time, but also collect the information of damages such as fatigue, corrosion, and wear of the wire rope in real time through AI technology, and analyze and process the collected big data to form detection reports such as the metal cross-sectional area loss rate at the damaged part of the wire rope, accurate positioning of the damage point, and electromagnetic waveform curve. Summary of the Invention

[0009] The present invention precisely aims at the problems existing in the prior art and provides a detection device for the main wire rope of a ship unloader. The technical solution has a simple structure, convenient operation, and effective control, and is composed of a stroke measurement device, a weak magnetic detection device, a magnetic memory planning device, an electric push rod, a data acquisition and conversion station, a system control main station, a touch screen, etc.

[0010] To achieve the above object, the technical solution of the present invention is as follows. A main wire rope detection device for a ship unloader, the detection device includes a stroke measurement device 5, a weak magnetic detection device 6, a magnetic memory planning device 7, a guide wheel assembly 8, a wire rope 9, a hydraulic push rod 10 and a control system; the weak magnetic detection device 6 is arranged between the stroke measurement device 5 and the magnetic memory planning device 7, and guide wheel assemblies 8 are arranged on both sides of the magnetic memory planning device 7. The stroke measurement device 5, the weak magnetic detection device 6, the magnetic memory planning device 7 and the guide wheel assembly 8 are all installed and fixed on a cross bar connected to the hydraulic push rod 10. When the ship unloader is in normal production, the wire rope 9 is above the detection device, maintaining a safe distance; when the main wire rope of the ship unloader is detected, the hydraulic push rod 10 is started to lift the entire detection device until it senses the wire rope 9 and stops. The wire rope 9 runs from right to left, first undergoes magnetic memory planning and then weak magnetic detection. During the detection, the wire rope 9 maintains a relative frictional movement with the guide wheel assembly 8.

[0011] As an improvement of the present invention, the control system includes a data acquisition conversion station, a control master station, a touch screen, a camera and a liquid crystal display. The control master station is installed in the PLC room of the machine room to analyze and process the large amount of data collected, and form detection reports such as the loss rate of the metal cross-sectional area at the damaged part of the wire rope, the accurate positioning of the damage point, and the electromagnetic waveform curve. The touch screen is an industrial control computer, which is used to control the up and down lines of the detection device in the detection system, view the detection results, and alarm for equipment failures. The camera is installed in the detection device area, divided into 2 on the river side and the land side, and is used for operators and ground equipment management personnel to observe the up and down line status of the detection device. The liquid crystal display is installed in the driver's cab and is used for displaying the pictures of the 2 cameras on the river side and the land side. Equipment management personnel can remotely connect to view the camera pictures and retrieve historical video monitoring through a mobile terminal.

[0012] A main wire rope detection method for a ship unloader sets four detection points. Among them, detection point 1 (upstream on the river side) and detection point 2 (downstream on the river side) are installed 2 meters in front of the fixed pulley on the river side girder, and are used to measure the closing wire rope B1 on the river side and the hoisting wire rope B2 on the river side respectively; detection point 3 (upstream on the land side) and detection point 4 (downstream on the land side) are installed 2 meters in front of the fixed pulley on the land side girder, and are used to measure the closing wire rope B4 on the land side and the hoisting wire rope B3 on the land side respectively.

[0013] As an improvement of the present invention, two data acquisition conversion stations are set, namely data acquisition conversion station 1 and data acquisition conversion station 2. Data acquisition conversion station 1 is installed near the areas of detection points 1 and 2 of the fixed pulley on the river side girder of the ship unloader, and data acquisition conversion station 2 is installed near the areas of detection points 3 and 4 of the fixed pulley on the land side girder of the ship unloader. The magnetic potential distribution of the 4 wire ropes and the wire rope position measurement data are collected and summarized to the system control master station in the machine room.

[0014] Compared with the prior art, the present invention has the following advantages

[0015] The wire rope detection system provided by the present invention can continuously and effectively detect the main wire rope of the ship unloader over a long distance. It is safe and reliable and is installed at the safety distance at the end of the hoisting stop limit and overtravel limit.

[0016] The wire rope detection system provided by the present invention has good operation stability, high detection efficiency and fast inspection speed. Compared with the traditional manual visual inspection and manual caliper static inspection, this system can perform dynamic detection, and the speed can reach 6 m / s.

[0017] The wire rope detection system provided by the present invention is provided with an upper and lower line function. The lower line does not affect the rapid operation of the wire rope and the maintenance of the wire rope. The upper line has a short operation cycle, and the entire detection can be completed in 5 minutes.

[0018] The wire rope detection system provided by the present invention has less workload, greatly reduces the work intensity of operators, automatically issues detection reports, and has a wire rope position measurement function, which is convenient for manual re-inspection.

[0019] For the wire rope detection system provided by the present invention, operators can check the equipment status and fault display through the touch screen computer screen, which is convenient for fault maintenance.

[0020] The wire rope detection system provided by the present invention has many technical advantages and can be technically promoted on port cranes. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 Installation position diagram of the detection device;

[0022] Figure 2 Detection path planning diagram;

[0023] Figure 3 Structure diagram of the detection system;

[0024] Figure 4 Schematic structural diagram of the detection device.

[0025] In the figure: 1. Detection point 1; 2. Detection point 2; 3. Detection point 3; 4. Detection point 4; 5. Travel measurement device; 6. Weak magnetic detection device; 7. Magnetic memory planning device; 8. Guide wheel assembly; 9. Wire rope; 10. Hydraulic push rod. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] In order to deepen the understanding of the present invention, the following detailed description is made in conjunction with the accompanying drawings for this embodiment.

[0027] Embodiment 1: Refer to Figure 1, A main wire rope detection device for a ship unloader. The detection device includes a stroke measurement device 5, a weak magnetic detection device 6, a magnetic memory planning device 7, a guide wheel assembly 8, a wire rope 9, a hydraulic push rod 10, and a control system. The weak magnetic detection device 6 is arranged between the stroke measurement device 5 and the magnetic memory planning device 7. Guide wheel assemblies 8 are arranged on both sides of the magnetic memory planning device 7. The stroke measurement device 5, the weak magnetic detection device 6, the magnetic memory planning device 7, and the guide wheel assembly 8 are all installed and fixed on a cross bar connected to the hydraulic push rod 10. During normal production of the ship unloader, the wire rope 9 is above the detection device, maintaining a safe distance. When detecting the main wire rope of the ship unloader, the hydraulic push rod 10 is started to lift the entire detection device until it senses the wire rope 9 and stops. The wire rope 9 runs from right to left, first undergoes magnetic memory planning and then weak magnetic detection. During detection, the wire rope 9 maintains a relative frictional movement with the guide wheel assembly 8.

[0028] The stroke measurement device is used for accurately positioning the damaged point. The magnetic memory planning device is used to apply an external magnetic field to the wire rope to form a "memory magnetic field". The weak magnetic detection device is used to calibrate the magnetic energy potential characteristic information memorized by the normal volume elements of the wire rope, collect damage information such as fatigue, corrosion, and wear of the wire rope, and analyze and process the collected large data to form detection reports such as the loss rate of the metal cross-sectional area at the damaged part of the wire rope, accurate positioning of the damaged point, and electromagnetic waveform curve.

[0029] The control system includes a data acquisition conversion station, a control master station, a touch screen, a camera, and a liquid crystal display. The control master station is installed in the PLC room of the machine room to analyze and process the collected large data to form detection reports such as the loss rate of the metal cross-sectional area at the damaged part of the wire rope, accurate positioning of the damaged point, and electromagnetic waveform curve. The touch screen is an industrial control computer used to control the up and down line of the detection device in the detection system, view the detection results, and alarm for equipment failures. The camera is installed in the detection device area and is divided into two, one on the river side and the other on the land side, for operators and ground equipment management personnel to observe the up and down line status of the detection device. The liquid crystal display is installed in the driver's cab and is used to display the images of the two cameras on the river side and the land side. Equipment management personnel can remotely connect to view the camera images and retrieve historical video monitoring through a mobile terminal.

[0030] A method for detecting the main steel wire rope of a ship unloader is provided, wherein four detection points are set, and the four detection points are 4 sets of independent detection devices, wherein detection points 1 (upstream on the river side) and 2 (downstream on the river side) are installed 2 meters in front of the fixed pulley of the beam on the river side, and respectively measure the opening and closing steel wire rope B1 on the river side and the lifting steel wire rope B2 on the river side; detection points 3 (upstream on the land side) and 4 (downstream on the land side) are installed 2 meters in front of the fixed pulley of the beam on the land side, and respectively measure the opening and closing steel wire rope B4 on the land side and the lifting steel wire rope B3 on the land side. The lifting rope and the opening and closing rope can complete the full rope detection in only two steps, and can detect 96% of the key working sections of the steel wire rope, which basically meets all the requirements for steel wire rope detection. There are two digital acquisition and conversion stations, namely digital acquisition and conversion station one and digital acquisition and conversion station two. Digital acquisition and conversion station one is installed near the one and two detection points of the fixed pulley on the river side of the ship unloader, and digital acquisition and conversion station two is installed near the three and four detection points of the fixed pulley on the land side of the ship unloader. It collects the magnetic energy potential distribution and wire rope position measurement data of the four steel ropes, and summarizes the data to the system control main station in the machine room.

[0031] Because the lifting wire rope and opening and closing wire rope of the ship unloader have large swings during normal lifting operation, in order to achieve good detection effect, the system adopts the working mode of slow wire rope operation and the device is online during detection; the wire rope runs quickly and the detection device is offline.

[0032] The detection equipment is installed at the fixed pulley of the beam on the river side. The wire rope at this position runs relatively stably, but there is a certain amount of vibration. The design uses an automatic lifting mechanism to bring the detection equipment online or offline to ensure that the detection equipment is not damaged.

[0033] Online during testing: The testing personnel operate the online button on the control end, the testing device automatically goes online, the wire rope runs stably at the testing speed (10% of full speed), and the system starts to automatically test the wire rope. Offline during non-testing: After each test is completed, the testing personnel operate the offline button on the control end, and the front-end testing device automatically goes offline without affecting the normal operation of the ship unloader.

[0034] When the wire rope is running at the fixed pulley on the land side, there is a certain angle and position change, so the detection method of follow-up + up and down lines is adopted, and the equipment is welded and fixed on the steel beam. In order to keep the wire rope stable and avoid damage to the detection equipment due to excessive swing of the wire rope, the guide wheel system is made of ultra-high molecular weight polyethylene with good wear resistance.

[0035] This technical solution makes full use of the existing mature mechanical transmission, electromagnetic induction, software automatic alarm and other technologies, takes intelligent control as the goal, and takes economy, practicality, safety and reliability as the premise, to solve the problems of poor operating safety and inadequate control of the main wire rope of the port crane, and improve the real-time and reliability of the safe operation control of the main wire rope of the ship unloader.

[0036] Working process: Determination process of the grab operation terminals ABCD: See Figure 2 , the position of grab operation terminal point A is the shore-side end stop limit of the ship unloader's main trolley + the grab ascending end limit (in special mode), the position of grab operation terminal point B is the river-side end stop limit of the ship unloader's main trolley + the grab ascending end limit (in special mode), the position of grab operation terminal point C is the river-side end stop limit of the ship unloader's main trolley + the grab descending end limit (in special mode), and the position of grab operation terminal point D is the shore-side end stop limit of the ship unloader's main trolley + the 0-meter horizontal reference position of the berth platform.

[0037] Working process of the detection device's online and offline: See Figure 1 , Figure 3 , Figure 4 , the inspector operates the online request instruction on the touch screen in the driver's cab. The 10 hydraulic push rod motors in the detection device are powered on and run. The hydraulic push rod pushes the detection device to rise. After the 8 guide wheel assemblies sense the wire rope, the motor stops running. The wire rope runs stably at the detection speed, and the system starts to detect the wire rope. After each detection is completed, the inspector operates the offline button at the control end. The 10 hydraulic push rod motors in the detection device are powered on and run to descend offline, without affecting the normal operation of the ship unloader.

[0038] Working process of the wire rope detection: See Figure 1 , Figure 2 , Figure 3 , Figure 4 , place the grab at the lowest position on the shore side, that is, point D; D→A: Measure points 1 and 2 are detected;

[0039] A→B: Measure points 1 and 2 are detected;

[0040] B→C: Measure points 3 and 4 are detected;

[0041] C→B: Measure points 1 and 2 are detected, repeated detection;

[0042] B→A: Measure points 3 and 4 are detected.

[0043] The effective detection distance of measuring point 1 for the river-side opening and closing wire rope B1 is the DA + AB section.

[0044] The effective detection distance of measuring point 2 for the river-side hoisting wire rope B2 is the DA + AB section.

[0045] The effective detection distance of measuring point 3 for the shore-side hoisting wire rope B4 is the CB + BA section.

[0046] The effective detection distance of measuring point 4 for the shore-side opening and closing wire rope B3 is the CB + BA section.

[0047] After the wire rope detection system runs, the 5-stroke metering device records the information of the effective detection distance section of the wire rope at the corresponding position for accurate positioning of the damage point; the 7 magnetic memory planning device uses the magnetic memory characteristics of ferromagnetic materials to actively plan a moderately quantified memory magnetic field; the 6 weak magnetic detection device continuously and uninterruptedly collects the information of the magnetic energy potential difference distributed and memorized in the wire rope volume element, and conducts big data quantitative analysis on various damages such as broken wires, wear, corrosion, and fatigue caused by the strength loss of the wire rope.

[0048] Under the background of the increasingly busy current production operations, through an intelligent technical solution, the intelligent detection of the main wire rope of the ship unloader is realized, so that the equipment stability is effectively controlled, and the equipment failure rate is controlled at a relatively low level. This is a very practical technical solution with great practical significance.

[0049] It should be noted that the above embodiments are not used to limit the protection scope of the present invention. Any equivalent transformation or substitution made on the basis of the above technical solutions falls within the protection scope of the claims of the present invention.

Claims

1. A main wire rope detection device for a ship unloader, characterized in that, the detection device includes a stroke measurement device, a weak magnetic detection device, a magnetic memory planning device, a guide wheel assembly, a wire rope, a hydraulic push rod and a control system; the weak magnetic detection device is arranged between the stroke measurement device and the magnetic memory planning device, and guide wheel assemblies are arranged on both sides of the magnetic memory planning device. The stroke measurement device, the weak magnetic detection device, the magnetic memory planning device and the guide wheel assembly are all fixedly installed on a cross bar connected to the hydraulic push rod. When the ship unloader is in normal production, the wire rope is above the detection device, maintaining a safe distance; when the main wire rope of the ship unloader is detected, the hydraulic push rod is started to lift the entire detection device until it senses the wire rope and stops. The wire rope runs from right to left, first performing magnetic memory planning and then weak magnetic detection. During the detection, the wire rope maintains a relative frictional movement with the guide wheel assembly.

2. The main wire rope detection device for a ship unloader according to claim 1, characterized in that, the control system includes a data acquisition and conversion station, a control master station, a touch screen, a camera and a liquid crystal display. The control master station is installed in the PLC room of the machine room to analyze and process the collected large data to form detection reports such as the loss rate of the metal cross-sectional area at the damaged part of the wire rope, the accurate positioning of the damage point, and the electromagnetic waveform curve. The touch screen is an industrial control computer, which is used to control the up and down line of the detection device in the detection system, view the detection results, and alarm for equipment failures. The camera is installed in the detection device area, divided into 2 on the river side and the land side, and is used for operators and ground equipment management personnel to observe the up and down line status of the detection device. The liquid crystal display is installed in the driver's cab and is used to display the pictures of the 2 cameras on the river side and the land side. Equipment management personnel can remotely connect to view the camera pictures and retrieve historical video monitoring through a mobile terminal.

3. A main wire rope detection method for a ship unloader, characterized in that, the detection device described in claim 1 or 2 is adopted, and four detection points are set. Among them, detection point 1 (upstream on the river side) and detection point 2 (downstream on the river side) are installed 2 meters in front of the fixed pulley on the river side girder, and are used to measure the opening and closing wire rope B1 and the hoisting wire rope B2 on the river side respectively; detection point 3 (upstream on the land side) and detection point 4 (downstream on the land side) are installed 2 meters in front of the fixed pulley on the land side girder, and are used to measure the opening and closing wire rope B4 and the hoisting wire rope B3 on the land side respectively.

4. The main wire rope detection method for a ship unloader according to claim 3, characterized in that, two data acquisition and conversion stations are set, namely data acquisition and conversion station 1 and data acquisition and conversion station 2. Data acquisition and conversion station 1 is installed near the areas of detection points 1 and 2 of the fixed pulley on the river side girder of the ship unloader, and data acquisition and conversion station 2 is installed near the areas of detection points 3 and 4 of the fixed pulley on the land side girder of the ship unloader. The magnetic potential distribution of the 4 wire ropes and the wire rope position measurement data are collected and the data is summarized to the system control master station in the machine room.

Images