Health diagnosis method and system for tensioning construction machinery based on online monitoring

Abstract

The present invention proposes a health diagnosis method and system for tensioning construction equipment based on online monitoring. An engineering IoT terminal with a flow meter is installed on the oil inlet line of the tensioning construction equipment. The engineering IoT terminal is connected to an application server and a cloud platform to monitor the operating status of the tensioning jack. During the operation of the tensioning jack, the system monitors the travel displacement of the tensioning jack's piston rod, whether there is oil leakage in the tensioning system composed of the tensioning jack and the hydraulic pump station, and whether the tensioning jack pump head has abnormal oil suction, thereby analyzing and determining the health of the tensioning jack. The present invention integrates the engineering IoT terminal into the tensioning construction equipment to achieve automated online monitoring of the tensioning construction equipment's operating status and automatic diagnosis of tensioning construction equipment failures. This solves the specific problems of manual maintenance, such as the difficulty, time-consuming, and low efficiency of troubleshooting. It also avoids the widespread and catastrophic engineering problems caused by "operating with faulty" tensioning construction equipment.

Description

Technical Field

[0001] The present invention belongs to the technical field of tensioning construction, and in particular relates to a health diagnosis method and system for tensioning construction machinery based on online monitoring. Background Art

[0002] The prestressed concrete engineering industry has mandatory requirements for quality acceptance and construction quality process control. Currently, quality acceptance for prestressed concrete projects relies on random sampling. Sampling rules are determined in advance, and inspectors conduct spot checks based on site preparations. This essentially eliminates the meaning of randomness, and reports of unqualified projects are rarely made, making their value very limited. Therefore, the quality of prestressed concrete projects is highly dependent on the operational performance of tensioning equipment (such as tensioning jacks).

[0003] Currently, there are no specific means or methods for monitoring the health of tensioning construction equipment. Even equipment failures are difficult to detect, let alone analyze and pinpoint. Tensioning construction equipment failures can generally be categorized into two types: one is inoperable, where the equipment's power system is inoperative. This can be determined by the displacement of the jack piston; the other is operational, but with quality deviations. The jack piston may be displaced, but the applied load and elongation are inaccurate. On-site assessments can only be made by measuring the elongation of the jack piston rod. This method provides only a rough understanding of the quality through simple measurements, making it impossible to pinpoint the cause of any quality issues, let alone determine the health of the construction equipment.

[0004] When it comes to prestressed construction quality, the use of intelligent tensioning equipment can cause widespread damage if equipment failures are not diagnosed in a timely manner. Human monitoring of prestressed tensioning equipment is inefficient, providing only a simple assessment of whether it is functioning properly and failing to assess its health based on behavioral data during operation. Even if personnel identify a malfunction through auxiliary means, it is difficult to analyze the cause and conduct timely repairs.

[0005] Related patents provide technical implementation methods for certain aspects, but they are not comprehensive and systematic enough for health diagnosis of prestressed and tensioned construction equipment. For example, CN117608274A discloses a method, system, equipment, and medium for diagnosing engineering machinery faults. These methods are used to classify and summarize faults in engineering machinery parts, providing a priority for problem resolution. However, they are not very targeted for the highly specialized prestressed and tensioned construction equipment. Another example is CN113700700A, which discloses a prestressed jack piston rod displacement measurement device and calculation method that uses the jack's oil inlet flow rate to measure the displacement of the jack piston rod. This method is used to measure the displacement of the jack piston rod and translate it into control of prestressed construction quality, but does not involve monitoring the condition and health of tensioned construction equipment. Summary of the Invention

[0006] The present invention aims to solve the technical problems existing in the prior art. The first purpose of the present invention is to provide a health diagnosis method for tensioning construction machinery based on online monitoring. The second purpose of the present invention is to provide a health diagnosis system for tensioning construction machinery based on online monitoring.

[0007] In order to achieve the above-mentioned first purpose, the present invention adopts the following technical solutions: a health diagnosis method for tensioning construction equipment based on online monitoring, the tensioning construction equipment is a tensioning jack, the oil inlet of the tensioning jack is connected to the hydraulic pump station through an oil inlet line, and an engineering Internet of Things terminal with a flow meter is provided on the oil inlet line. The engineering Internet of Things terminal is connected to the data server through a data transmission module, and the data server is connected to the application server and the cloud platform. The application server and the cloud platform display the operating status of the tensioning jack, thereby realizing the monitoring of the operating status of the tensioning jack; during the working process of the tensioning jack, the stroke displacement of the piston rod of the tensioning jack and whether the tensioning system composed of the tensioning jack and the hydraulic pump station is monitored Oil leakage, whether the tensioning jack pump head has abnormal oil absorption, analyze and judge the health of the tensioning jack, the specific methods are as follows: Piston rod stroke displacement monitoring: obtain the stroke displacement of the tensioning jack piston rod through the value of the flow meter, and when the stroke displacement of the piston rod reaches the high stroke threshold, issue an early warning to protect the tensioning jack and achieve healthy stress; whether there is oil leakage in the tensioning system: judge whether the tensioning system has oil leakage according to the difference between the process flow volume of the tensioning jack and the return flow volume of the tensioning jack; whether the tensioning jack pump head has abnormal oil absorption: when the tensioning jack pump head is equipped with n oil nozzles, judge whether the pump head has abnormal oil absorption and the number of damaged oil nozzles according to the proportion of the actual flow of the oil inlet circuit in the theoretical flow.

[0008] The above technical solution integrates the engineering Internet of Things terminal into the tensioning construction equipment, realizes automated online monitoring of the operating status of the tensioning construction equipment, and automatically diagnoses the failure problems of the tensioning construction equipment. It solves the specific problems of difficulty, time and low efficiency in troubleshooting during manual maintenance, and avoids large-scale catastrophic engineering problems caused by the "sick operation" of the tensioning construction equipment.

[0009] In a preferred embodiment of the present invention, the stroke displacement of the piston rod is monitored in the following manner: L=V / A, wherein L is the stroke displacement of the piston rod, V is the flow rate of the oil inlet circuit, and A is the nominal cross-sectional area of ​​the piston rod.

[0010] The above technical solution is based on the flow data collected by the engineering Internet of Things terminal, and uses the flow of the oil inlet line and the cross-sectional area of ​​the piston rod to calculate the stroke of the tensioning jack. When it exceeds a certain safety threshold, a protection mechanism is set to issue a safety warning.

[0011] In a preferred embodiment of the present invention, whether there is oil leakage in the tensioning system is determined in the following manner: V + -V - >0, it means there is oil leakage in the tensioning system, otherwise it means there is no oil leakage in the tensioning system. + is the flow volume of the tensioning jack process, V - is the return flow volume of the tensioning jack.

[0012] The above technical solution is based on the flow data collected by the engineering Internet of Things terminal and uses the measured difference in oil inlet and return flow to diagnose whether there is oil leakage or looseness in the tensioning system during the construction process.

[0013] In a preferred embodiment of the present invention, whether the tensioning jack pump head has abnormal oil absorption is determined in the following manner: the actual flow rate of the oil inlet oil circuit is V, the theoretical flow rate of the oil inlet oil circuit is Vn, V=Vn indicates normal oil absorption, V<Vn indicates abnormal oil absorption; if the oil absorption is abnormal, it is determined to be The value closest to The value of The oil nozzle is damaged and does not absorb oil. =1, 2, ..., n, where n is the number of nozzles.

[0014] The above technical solution is based on the flow data collected by the engineering Internet of Things terminal. It uses the oil inlet flow rate to determine the oil suction capacity of the plunger pump, diagnose the normal or abnormal condition of the pump head, and can also specifically diagnose the number of damaged oil nozzles.

[0015] In a preferred embodiment of the present invention, whether the tensioning jack piston rod is in the extension process or the retraction return process is judged according to the following method: tensioning jack process judgment: the flow meter works in the forward direction, the test data is a natural number, and the marking direction is "+"; tensioning jack return judgment: the flow meter works in the reverse direction, the test data is a natural number, and the marking direction is "-".

[0016] The above technical solution determines whether the tensioning jack is in the forward stroke or the return stroke by the direction of the flow meter, which is simple and quick.

[0017] In a preferred embodiment of the present invention, when there are multiple tensioning jacks of different specifications at a construction site, each tensioning jack is numbered, and the oil supply per unit time of the oil inlet circuit of the tensioning jack of corresponding specifications is stored according to the specifications of each tensioning jack. When the tensioning jack is working, the stored oil supply per unit time is used to determine whether the specifications of the tensioning jack match. If they do not match, an alarm is issued.

[0018] The above technical solution stores the oil supply per unit time (i.e., oil inlet flow) of the oil inlet circuit of the tensioning jack, and memorizes the oil inlet flow of each tensioning jack at the construction site. When a difference in the oil inlet flow appears after the tensioning jack is replaced, it is determined that the tensioning jack is mismatched and an alarm is issued to avoid the cross-use of the tensioning jacks, which is also beneficial to the use and management of the tensioning jacks at the construction site.

[0019] In order to achieve the above-mentioned second purpose, the present invention adopts the following technical solution: a health diagnosis system for tensioning construction equipment based on online monitoring, an engineering Internet of Things terminal with a flow meter installed on the oil inlet line of the tensioning construction equipment, the engineering Internet of Things terminal is connected to the data server through a data transmission module, the data server is connected to the application server and the cloud platform, and the application server and the cloud platform display the operating status of the tensioning jack; the engineering Internet of Things terminal or the data server adopts the diagnostic method described in the present invention to detect the health of the tensioning construction equipment.

[0020] In another preferred embodiment of the present invention, the engineering Internet of Things terminal includes a flow meter, a data storage device, a controller, a power supply system and a mechanical housing. The signal output end of the flow meter is connected to the controller, the controller is connected to the data storage device, the output end of the data storage device is connected to the data transmission module, the flow meter, data storage device, controller and power supply system are integrated in the mechanical housing, and the power supply system supplies power to the flow meter, data storage device and controller.

[0021] The above technical solution integrates the flow meter, data storage device, controller and power supply system in the mechanical housing to form an engineering Internet of Things terminal, which is convenient for installing the engineering Internet of Things terminal as a whole on the oil inlet line. The installation is convenient, and the engineering Internet of Things terminal is universal and highly versatile.

[0022] In another preferred embodiment of the present invention, the flow meter is a vector flow meter for measuring the volume and direction of the hydraulic oil of the tensioning jack.

[0023] The above technical solution uses a high-precision vector flowmeter to measure the oil inlet flow and return flow of the tensioning system, and identifies and marks the direction of hydraulic oil movement to facilitate judgment of whether the piston rod is extended or retracted.

[0024] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments with reference to the accompanying drawings, in which:

[0026] Figure 1It is a principle block diagram of a diagnostic system for tensioning construction equipment according to an embodiment.

[0027] Figure 2 This is a schematic diagram of the health diagnosis results of tensioning construction equipment. DETAILED DESCRIPTION

[0028] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0029] In the description of the present invention, it should be understood that the terms "longitudinal", "transverse", "vertical", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0030] In the description of the present invention, unless otherwise specified and limited, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a mechanical connection or an electrical connection, or it can be the internal communication between two components. It can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to the specific circumstances. Example 1

[0031] This embodiment provides a health diagnosis method for tensioning construction equipment based on online monitoring, such as Figure 1As shown, in the present invention, the tensioning construction tool is a tensioning jack, and the oil inlet of the tensioning jack is connected to the hydraulic pump station via an oil inlet line. This is prior art and will not be described in detail here. An engineering Internet of Things terminal with a flow meter (a vector flow meter is used to measure the volume and direction of the hydraulic oil in the tensioning jack) is provided on the oil inlet line for online monitoring of the operating data of the tensioning jack. The engineering Internet of Things terminal is connected to a data server via a data transmission module. For example, a data transmission module including but not limited to a 5G network is installed on the engineering Internet of Things terminal for wireless transmission, thereby achieving the collection and transmission of hydraulic oil flow data on the oil inlet line during the tensioning construction process. The data server is used to store and manage data and provide database services. The data server is connected to an application server and a cloud platform. The application server and the cloud platform are used to run and manage business applications, provide various business functions and services, and display the operating status of the tensioning jack by the application server and the cloud platform, thereby enabling monitoring of the operating status of the tensioning jack.

[0032] During the operation of the tensioning jack, the displacement of the piston rod of the tensioning jack, whether there is oil leakage in the tensioning system composed of the tensioning jack and the hydraulic pump station, and whether the tensioning jack pump head has abnormal oil absorption are monitored. The flow data collected by the engineering IoT terminal is transmitted to the data server through the data transmission module. The application server and cloud platform call the data received by the data server and diagnose the health status of the tensioning jack through the algorithm. The specific method is as follows:

[0033] Piston rod travel monitoring: L = V / A, where L is the piston rod travel, V is the oil inlet flow rate (volume flow), and A is the nominal cross-sectional area of ​​the piston rod. This system uses flowmeter readings to determine the travel of the tensioning jack's piston rod. When the piston rod travel reaches a high threshold (e.g., 195mm), an early warning is issued to protect the tensioning jack and maintain healthy stress levels.

[0034] Is there any oil leakage in the tensioning system: V + -V - >0, it means there is oil leakage in the tensioning system, otherwise it means there is no oil leakage in the tensioning system. + is the flow volume of the tensioning jack process, V - The present invention diagnoses whether there is oil leakage or non-sealing of the tensioning system during the construction process based on the difference between the process flow volume of the tensioning jack and the return flow volume of the tensioning jack.

[0035] Whether the tensioning jack pump head has abnormal oil absorption: When the tensioning jack pump head is equipped with n oil nozzles, the actual flow of the oil inlet circuit is V (measured by the flow meter of the engineering Internet of Things terminal), and the theoretical flow of the oil inlet circuit is Vn (the flow of the oil inlet circuit mainly goes to the oil cylinder of the tensioning jack. The theoretical flow is Vn calculated based on the product of the extended length of the piston rod and the nominal cross-sectional area of ​​the piston rod. The extended length of the piston rod can be obtained by the detection unit that measures the elongation of the prestressed steel strand during construction, or by setting a distance sensor to measure it. The extended length of the piston rod is equal to the elongation of the prestressed steel strand). V=Vn means that the oil absorption is normal, and V<Vn means that the oil absorption is abnormal. If the oil absorption is abnormal, determine The value closest to The value of The oil nozzle is damaged and does not absorb oil. =1, 2, ..., n, where n is the number of nozzles. For example = If one of the oil nozzles is damaged and does not absorb oil, = When the oil flow rate is less than 100%, two oil nozzles are damaged and cannot absorb oil, and so on. The present invention determines whether the pump head has abnormal oil absorption and the number of damaged oil nozzles according to the ratio of the actual flow rate of the oil inlet circuit to the theoretical flow rate.

[0036] In the present invention, whether the tensioning jack piston rod is in the extension process or the retraction return process is judged according to the following method: tensioning jack process judgment: the flow meter works in the forward direction, the test data is a natural number, and the marking direction is "+"; tensioning jack return judgment: the flow meter works in the reverse direction, the test data is a natural number, and the marking direction is "-".

[0037] like Figure 2 As shown, in another preferred embodiment of the present invention, a label is provided in the data server corresponding to each fault, and the label corresponds to the fault one-to-one, which is convenient for subsequent analysis and investigation of the cause of the tensioning construction equipment fault and maintenance.

[0038] In actual application, for a construction site equipped with multiple tensioning construction machines (or a hydraulic pump station equipped with multiple tensioning construction machines), an engineering Internet of Things terminal is installed on the oil inlet line of each tensioning construction machine. All engineering Internet of Things terminals are connected to the data server through a data transmission module, and the operating status of multiple tensioning construction machines is monitored through the application server and cloud platform.

[0039] Preferably, the application server and the cloud platform have a memory function to memorize the oil inlet flow of all tensioning jacks. When there are multiple tensioning jacks of different specifications on the construction site, the tensioning jacks at each location are numbered, and according to the specifications of the tensioning jacks at each location, the oil supply per unit time of the oil inlet circuit of the tensioning jack of the corresponding specification is stored (that is, the oil inlet flow of the tensioning jack at that location is stored). When the tensioning jack is working, the actual oil inlet flow of the tensioning jack is compared with the stored oil supply per unit time to determine whether the specifications of the tensioning jack match. If they do not match, an alarm is issued (such as a sound alarm to alert the number of the unmatched tensioning jack) to avoid the cross-use of tensioning jacks. Example 2

[0040] This embodiment provides a health diagnosis system for tensioning construction equipment based on online monitoring, which uses the diagnosis method of embodiment 1 for detection. Figure 1 As shown, the diagnostic system includes an engineering Internet of Things terminal installed on the oil inlet line of the tensioning construction equipment. The engineering Internet of Things terminal is connected to the data server through a data transmission module. The data server is connected to the application server and the cloud platform. The application server and the cloud platform display the operating status of the tensioning jack. The engineering Internet of Things terminal or the data server uses the diagnostic method of the present invention to detect the health of the tensioning construction equipment.

[0041] The engineering IoT terminal includes a flowmeter, data storage, controller, power supply system, and mechanical housing. The flowmeter uses a high-precision vector flowmeter to measure the volume and direction of the tensioning jack's hydraulic oil. The flowmeter's signal output is connected to the controller, which is connected to the data storage, and the data storage's output is connected to the data transmission module. The flowmeter, data storage, controller, and power supply system are integrated into the mechanical housing, and the power supply system provides power to the flowmeter, data storage, and controller. Preferably, the data transmission module is also integrated into the mechanical housing and powered by the power supply system.

[0042] Throughout this specification, reference to terms such as "preferred embodiment," "one embodiment," "some embodiments," "example," "specific example," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0043] While 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 invention, and that the scope of the invention is defined by the claims and their equivalents.

Claims

1. A health diagnosis method for tensioning construction equipment based on online monitoring, characterized in that: The tensioning construction machine is a tensioning jack, the oil inlet of the tensioning jack is connected to the hydraulic pump station through an oil inlet line, an engineering Internet of Things terminal with a flow meter is provided on the oil inlet line, the engineering Internet of Things terminal is connected to a data server through a data transmission module, the data server is connected to an application server and a cloud platform, and the application server and the cloud platform display the operating status of the tensioning jack, thereby realizing monitoring of the operating status of the tensioning jack; During the operation of the tensioning jack, monitor the stroke displacement of the piston rod of the tensioning jack, whether there is oil leakage in the tensioning system composed of the tensioning jack and the hydraulic pump station, whether there is abnormal oil absorption of the tensioning jack pump head, and analyze and judge the health of the tensioning jack. The specific methods are as follows: Piston rod stroke displacement monitoring: The flow meter value is used to obtain the stroke displacement of the tensioning jack piston rod. When the piston rod stroke displacement reaches the high stroke threshold, an early warning is issued to protect the tensioning jack and ensure healthy stress. Whether there is oil leakage in the tensioning system: judge whether there is oil leakage in the tensioning system based on the difference between the process flow volume of the tensioning jack and the return flow volume of the tensioning jack; Whether the tensioning jack pump head has abnormal oil absorption: When the tensioning jack pump head is equipped with n oil nozzles, judge whether the pump head has abnormal oil absorption and the number of damaged oil nozzles based on the proportion of the actual flow rate of the oil inlet line to the theoretical flow rate; When there are multiple tensioning jacks of different specifications at a construction site, each tensioning jack is numbered, and the oil supply per unit time of the oil inlet circuit of the corresponding specification is stored according to the specifications of each tensioning jack. When the replaced tensioning jack is working, the stored oil supply per unit time is used to determine whether the specifications of the tensioning jack match. If not, an alarm is issued.

2. The method for diagnosing the health of tensioning construction equipment based on online monitoring according to claim 1 is characterized in that: The piston rod travel displacement monitoring adopts the following method: L=V / A, where L is the stroke displacement of the piston rod, V is the flow rate of the oil inlet circuit, and A is the nominal cross-sectional area of ​​the piston rod.

3. The method for diagnosing the health of tensioning construction equipment based on online monitoring according to claim 1 is characterized in that: Whether there is oil leakage in the tensioning system is determined by the following method: V + -V - >0, it means there is oil leakage in the tensioning system, otherwise it means there is no oil leakage in the tensioning system. + is the flow volume of the tensioning jack process, V - is the return flow volume of the tensioning jack.

4. The method for diagnosing the health of tensioning construction equipment based on online monitoring according to claim 1, characterized in that: Whether the tensioning jack pump head has abnormal oil absorption is determined in the following manner: The actual flow rate of the oil inlet circuit is V, and the theoretical flow rate of the oil inlet circuit is Vn. V=Vn indicates normal oil suction, and V<Vn indicates abnormal oil suction. If the oil absorption is abnormal, confirm The value closest to If the value of , then x nozzles are damaged and do not absorb oil, x = 1, 2, ..., n, where n is the number of nozzles.

5. The method for diagnosing the health of tensioning construction equipment based on online monitoring according to claim 1 is characterized in that: Determine whether the tensioning jack piston rod is in the process of extending or retracting according to the following methods: Tension jack progress judgment: the flow meter works in the forward direction, the test data is a natural number, and the marking direction is "+"; Judgment of the return stroke of the tensioning jack: the flow meter works in the reverse direction, the test data is a natural number, and the marking direction is "-".

6. The health diagnosis system of tensioning construction equipment based on online monitoring is characterized by: It includes an engineering Internet of Things terminal with a flow meter installed on the oil inlet line of the tensioning construction equipment. The engineering Internet of Things terminal is connected to the data server through a data transmission module. The data server is connected to the application server and the cloud platform. The application server and the cloud platform display the operating status of the tensioning jack; The engineering Internet of Things terminal or data server uses the diagnostic method described in any one of claims 1-5 to detect the health of the tensioning construction machinery.

7. The online monitoring-based health diagnosis system for tensioning construction equipment according to claim 6 is characterized in that: The engineering Internet of Things terminal includes a flow meter, a data storage device, a controller, a power supply system and a mechanical housing. The signal output end of the flow meter is connected to the controller, the controller is connected to the data storage device, and the output end of the data storage device is connected to the data transmission module. The flow meter, data storage device, controller and power supply system are integrated in the mechanical housing, and the power supply system supplies power to the flow meter, data storage device and controller.

8. The online monitoring-based health diagnosis system for tensioning construction equipment according to claim 7 is characterized in that: The flow meter is a vector flow meter, which is used to measure the volume and direction of the hydraulic oil of the tensioning jack.

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