Overload protection early warning system for material lifting and transportation

Abstract

The invention relates to the technical field of overload early warning, in particular to a material lifting transportation overload protection early warning system. Comprising a data acquisition module which is used for monitoring the load condition of transportation equipment in real time and comprises a weight acquisition device, a current sensor, an acceleration sensor, a vibration sensor and a displacement sensor; the control module is connected with the data acquisition module, and is used for secondarily judging whether the equipment has the overload condition or not according to the offset of the material reaching the preset point position when the equipment has the overload condition according to the dynamic load characteristic value, or reducing the acceleration of starting the equipment, and reducing the acceleration of starting the equipment when the secondary judgment equipment has the overload condition. Determining an overload reason according to the current fluctuation value of the motor; and the early warning module is connected with the control module and is used for sending out an early warning signal according to a judgment result of the control module. According to the invention, the sensitivity of the overload protection early warning system is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of overload warning, and particularly relates to a material lifting and transporting overload protection warning system. Background Art

[0002] In the field of material lifting and transporting, such as construction sites, warehousing logistics, and industrial production scenarios, the load control of vertical transportation equipment is directly related to operation safety and equipment life. Traditional material hoists mostly rely on manual estimation or simple mechanical overload protection devices, which have problems such as lagging response, insufficient accuracy, high false alarm rate, and inability to give real-time warnings.

[0003] Chinese Patent Application Publication No.: CN112320262A, discloses an overload warning method for a main coal transportation device in a coal mine, aiming to solve the technical problem that the existing main coal transportation system is prone to overload shutdown. The following technical solutions are adopted: 1) Calculate the real-time coal load on the warning belt; 2) Read the real-time power value on the warning belt; 3) Take the real-time coal load calculated in step 1) and the real-time power value read in step 2) at the same moment as a pair of data, and obtain at least 200 pairs of data within a continuous period of a fixed duration, and this continuous period is continuously updated with the current moment as the end; 4) Use the least squares method to perform linear fitting on the above data to obtain the relationship between the coal load and the power of the warning belt; 5) Estimate the coal load after X minutes; 6) Calculate the power value of the warning belt after X minutes, and compare this power value of the warning belt with a preset value.

[0004] However, the following problems exist in the prior art: The prior art does not consider the real-time operating state of the equipment and environmental interference factors, resulting in insufficient warning sensitivity. Summary of the Invention

[0005] Therefore, the present invention provides a material lifting and transporting overload protection warning system to overcome the problem of insufficient warning sensitivity caused by the prior art not considering the real-time operating state of the equipment and environmental interference factors.

[0006] To achieve the above object, the present invention provides a material lifting and transporting overload protection warning system, including: A data acquisition module, which is used to monitor the load information of the transportation equipment in real time, including a weight acquisition device for measuring the load weight, a current sensor for monitoring the current fluctuation of the motor, an acceleration sensor for monitoring the starting acceleration of the equipment, a vibration sensor for monitoring the vibration amplitude of the equipment, and a displacement sensor for obtaining the material transportation position; A control module, which is connected to the data acquisition module, is used to determine whether the device is overloaded according to the dynamic load characteristic value obtained by the data acquisition module. If there is an overloaded condition, it is used to re-determine whether the device is overloaded according to the offset of the material reaching the preset point, or reduce the acceleration of the device startup, and determine the cause of the overload according to the current fluctuation value of the motor based on the result of re-determining that the device is overloaded. An early warning module, which is connected to the control module, is used to send out an early warning signal and perform corresponding early warning actions according to the determination result of the control module.

[0007] Further, the control module determines whether the device is overloaded according to the dynamic load characteristic value under the condition that the device load rate is less than the preset load rate, where if the dynamic load characteristic value is less than the first preset load threshold, it is determined that the device is not overloaded, and the transportation continues according to the current parameters; if the dynamic load characteristic value is greater than or equal to the first preset load threshold and less than the second preset load threshold, it is determined that the device is overloaded, and it is re-determined whether the device is overloaded according to the offset generated when the material reaches the preset point; if the dynamic load characteristic value is greater than or equal to the second preset load threshold, it is determined that the device is overloaded, the transportation is paused, and the acceleration of the device startup is reduced according to the difference between the dynamic load characteristic value and the second preset load threshold.

[0008] Further, the dynamic load characteristic value is jointly determined by the dynamic load coefficient and the startup acceleration.

[0009] Further, the control module starts the first-level early warning under the condition that the device load rate is greater than or equal to the preset load rate.

[0010] Further, the control module re-determines whether the device is overloaded according to the offset generated when the material reaches the preset point, where if the offset is less than the first preset offset, it is re-determined that the device is not overloaded, and the transportation continues according to the current parameters; if the offset is greater than or equal to the first preset offset and less than the second preset offset, it is re-determined that the device is overloaded, and the cause of the overload is determined according to the current fluctuation value of the motor; if the offset is greater than or equal to the second preset offset, it is re-determined that the device is overloaded, and the second-level early warning is started.

[0011] Further, the control module sets several adjustment methods for the acceleration of the device startup, and each adjustment method has a different reduction amplitude for the acceleration.

[0012] Further, the control module determines the overload cause according to the current fluctuation value of the motor, wherein, if the current fluctuation value is less than the preset current fluctuation value, it is determined that the overload cause is uneven material distribution, and the motor speed is reduced according to the difference between the preset current fluctuation value and the current fluctuation value; if the current fluctuation value is greater than or equal to the preset current fluctuation value, it is determined that the overload cause is poor environmental conditions, and a three - level warning is initiated.

[0013] Further, the control module determines the qualification of acceleration adjustment according to the vibration amplitude under the first preset condition, wherein, if the vibration amplitude is less than the preset vibration amplitude, it is determined that the adjustment of the acceleration is qualified; if the vibration amplitude is greater than or equal to the preset vibration amplitude, it is determined that the adjustment of the acceleration is unqualified, and the second preset load threshold is reduced according to the difference between the vibration amplitude and the preset vibration amplitude; The first preset condition is that the device completes the adjustment of the acceleration.

[0014] Further, the second preset load threshold is positively correlated with the vibration amplitude difference, where the vibration amplitude difference is the difference between the vibration amplitude and the preset vibration amplitude.

[0015] Further, the first - level warning is a high - risk warning, and transportation needs to be immediately suspended and the load weight reduced; the second - level warning is a medium - risk warning, and transportation parameters need to be adjusted; the third - level warning is a low - risk warning, and the transportation status needs to be determined according to the actual environmental conditions.

[0016] Compared with the prior art, the beneficial effects of the present invention are that the present invention uses the data acquisition module to monitor the load condition of the transportation device in real time, and the control module adjusts the device operation parameters in real time according to the data obtained by the data acquisition module to ensure that the device operates within a safe range.

[0017] Further, the present invention sets up a three - level warning mechanism, which can take corresponding measures according to different overload risk levels. This hierarchical warning mechanism can effectively avoid false alarms and missed alarms and improve the accuracy of the warning.

[0018] Further, the present invention introduces a dynamic load characteristic value to determine whether the device is overloaded, which is jointly determined by the load weight and the dynamic load coefficient, and can more accurately reflect the actual load state of the device, avoiding misjudgment caused by environmental interference or changes in the device operation state.

[0019] Furthermore, after initially determining that the device is overloaded, the present invention makes a secondary determination based on the offset of the material reaching the preset point to further confirm the overloaded situation, improving the reliability of the system through a dual determination mechanism and reducing the possibility of misjudgment.

[0020] Furthermore, the present invention analyzes the cause of overload based on the current fluctuation value of the motor and takes corresponding measures to solve the problem targeted.

[0021] Furthermore, through real-time monitoring and dynamic adjustment, the system of the present invention can effectively avoid damage to the device caused by overload or improper operation, extend the service life of the device, and ensure the safety of operators at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the module connection of the material lifting and transporting overload protection warning system according to an embodiment of the present invention; Figure 2 It is a flowchart for determining whether there is an overload condition of the device according to an embodiment of the present invention; Figure 3 It is a flowchart for secondary determination of whether there is an overload condition of the device according to an embodiment of the present invention; Figure 4 It is a flowchart for determining the cause of overload according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0023] In order to make the purpose and advantages of the present invention clearer, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0024] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principle of the present invention and do not limit the protection scope of the present invention.

[0025] It should be noted that the data in this embodiment are all obtained through comprehensive analysis and evaluation of the historical detection data and corresponding historical detection results in the three months before this detection by the present invention. Those skilled in the art can understand that the determination method of the present invention for a single above-mentioned parameter can be to select the value with the highest proportion according to the data distribution as the preset standard parameter, use weighted summation to take the obtained value as the preset standard parameter, substitute each historical data into a specific formula and take the value obtained by using this formula as the preset standard parameter or other selection methods, as long as it meets the requirement that the present invention can clearly define different specific situations in the single determination process through the obtained values.

[0026] Please refer to Figures 1 to 4As shown, they are respectively the schematic diagram of module connection of the overload protection and early warning system for material lifting and transportation in the embodiment of the present invention; the flowchart for determining whether there is an overload condition of the device in the embodiment of the present invention; the flowchart for secondary determination of whether there is an overload condition of the device in the embodiment of the present invention; the flowchart for determining the cause of overload in the embodiment of the present invention.

[0027] The overload protection and early warning system for material lifting and transportation in the embodiment of the present invention includes: A data acquisition module, which is used to monitor the load information of the transportation device in real time, including a weight acquisition device for measuring the load weight, a current sensor for monitoring the motor current fluctuation, an acceleration sensor for monitoring the device startup acceleration, a vibration sensor for monitoring the device vibration amplitude, and a displacement sensor for obtaining the material transportation position; A control module, which is connected to the data acquisition module, and is used to determine whether there is an overload condition of the device according to the dynamic load characteristic value obtained by the data acquisition module. If there is an overload condition, it is used to secondarily determine whether there is an overload condition of the device according to the offset amount of the material reaching the preset point, or reduce the acceleration of the device startup, and determine the cause of overload according to the current fluctuation value of the motor according to the result of the secondary determination that there is an overload condition of the device; An early warning module, which is connected to the control module, and is used to send out an early warning signal and execute corresponding early warning actions according to the determination result of the control module.

[0028] Specifically, the weight acquisition device is, for example, a strain type weighing sensor, a hydraulic pressure sensor, a wire rope tension sensor, and is not specifically limited.

[0029] Specifically, the control module determines whether there is an overload condition of the device according to the dynamic load characteristic value under the condition that the device load rate is less than the preset load rate of 80%. Among them, if the dynamic load characteristic value is less than the first preset load threshold of 1.2, it is determined that the device does not have an overload situation, and the transportation continues according to the current parameters; If the dynamic load characteristic value is greater than or equal to the first preset load threshold and less than the second preset load threshold of 1.8, it is determined that the device has an overload situation, and it is secondarily determined whether there is an overload condition of the device according to the offset amount generated when the material reaches the preset point; If the dynamic load characteristic value is greater than or equal to the second preset load threshold, it is determined that the device has an overload situation, and the transportation is paused, and the acceleration of the device startup is reduced according to the difference between the dynamic load characteristic value and the second preset load threshold.

[0030] Specifically, the load rate is the ratio of the current load to the preset load, and the current load is obtained through the weight acquisition device.

[0031] In the embodiment of the present invention, the preset load value is 10t, the preset load rate value is 80%, the first preset load threshold value is 1.2, and the second preset load threshold value is 1.8. However, the above values are not limited thereto, and those skilled in the art can adjust the values according to actual needs.

[0032] Specifically, the dynamic load characteristic value is jointly determined by the dynamic load coefficient and the starting acceleration, and is calculated by the following formula: , where , in the formula, K is the dynamic load coefficient, a is the starting acceleration, g is the acceleration due to gravity, and g is set to 9.8 m / s². is the first weight coefficient, and is set to , is the vibration amplitude, is the vibration amplitude threshold, and is set to , is the second weight coefficient, and is set to , is the average current value, is the current threshold, and is set to .

[0033] Specifically, the control module starts the first-level warning under the condition that the equipment load rate is greater than or equal to the preset load rate.

[0034] Specifically, the control module secondarily determines whether the equipment is overloaded according to the offset generated when the material reaches the preset point. Among them, if the offset is less than the first preset offset of 10mm, it is secondarily determined that the equipment is not overloaded, and the transportation continues according to the current parameters; If the offset is greater than or equal to the first preset offset and less than the second preset offset, it is secondarily determined that the equipment is overloaded, and the cause of the overload is determined according to the current fluctuation value of the motor; If the offset is greater than or equal to the second preset offset, it is secondarily determined that the equipment is overloaded, and the second-level warning is started.

[0035] In the embodiment of the present invention, the first preset offset value is 10mm, and the second preset offset value is 20mm. However, the above values are not limited thereto, and those skilled in the art can adjust the values according to actual needs.

[0036] Specifically, the offset is obtained by the displacement sensor in the data acquisition module.

[0037] Specifically, the control module has several adjustment methods for the acceleration at device startup, and each adjustment method has a different reduction amplitude for the acceleration. Among them, if the dynamic load difference is less than the first preset dynamic load difference of 0.2, the first acceleration adjustment coefficient of 0.95 is used to reduce the acceleration to the corresponding value; If the dynamic load difference is greater than or equal to the first preset dynamic load difference and less than the second preset dynamic load difference of 0.5, the second acceleration adjustment coefficient of 0.87 is used to reduce the acceleration to the corresponding value; If the dynamic load difference is greater than or equal to the second preset dynamic load difference, the third acceleration adjustment coefficient of 0.78 is used to reduce the acceleration to the corresponding value; The dynamic load difference is the difference between the dynamic load characteristic value and the second preset load threshold.

[0038] In the embodiment of the present invention, the initial acceleration is set to 2 m / s 2 , the first preset dynamic load difference is taken as 0.2, and the second preset dynamic load difference is taken as 0.5. However, the above values are not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0039] Specifically, the control module determines the overload cause according to the current fluctuation value of the motor. Among them, if the current fluctuation value is less than the preset current fluctuation value, it is determined that the overload cause is uneven material distribution, and the motor speed is reduced according to the difference between the preset current fluctuation value and the current fluctuation value; If the current fluctuation value is greater than or equal to the preset current fluctuation value of 0.5 A, it is determined that the overload cause is poor environmental conditions, and a three - level warning is started.

[0040] Specifically, the current fluctuation value is the standard deviation of the current of the preset sampling quantity in a single transportation. The first sample is taken when the device is started, and then samples are taken every same time interval. The specific time interval is not limited.

[0041] In the embodiment of the present invention, the preset current fluctuation value is taken as 0.5 A, and the preset sampling quantity is set to 20. However, the above values are not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0042] Specifically, the motor speed is reduced according to the current fluctuation difference. Among them, if the current fluctuation difference is less than the first preset current fluctuation difference of 0.1 A, the first speed adjustment coefficient of 0.96 is used to reduce the motor speed to the corresponding value; If the current fluctuation difference is greater than or equal to the first preset current fluctuation difference and less than the second preset current fluctuation difference of 0.2 A, the second speed adjustment coefficient of 0.90 is used to reduce the motor speed to the corresponding value; If the difference in current fluctuations is greater than or equal to the second preset current fluctuation difference, the motor speed is reduced to the corresponding value using the third speed adjustment coefficient of 0.83; The difference between the preset current fluctuation value and the current fluctuation value.

[0043] In an embodiment of the present invention, the initial motor speed is set to 1000 r / min, the first preset current fluctuation difference is taken as 0.1 A, and the second preset current fluctuation difference is taken as 0.2 A. However, the above values are not limited thereto, and those skilled in the art can adjust the values according to actual needs.

[0044] Specifically, the control module determines the qualification of acceleration adjustment under the first preset condition. Among them, if the vibration amplitude is less than the preset vibration amplitude of 0.5 mm, it is determined that the acceleration adjustment is qualified; If the vibration amplitude is greater than or equal to the preset vibration amplitude, it is determined that the acceleration adjustment is unqualified, and the second preset load threshold is reduced according to the difference between the vibration amplitude and the preset vibration amplitude; The first preset condition is that the equipment completes the acceleration adjustment.

[0045] In an embodiment of the present invention, the preset vibration amplitude is taken as 0.5 mm. However, the above value is not limited thereto, and those skilled in the art can adjust the value according to actual needs.

[0046] Specifically, the second preset load threshold is positively correlated with the vibration amplitude difference. Among them, if the vibration amplitude difference is less than the first preset vibration amplitude difference of 0.1 mm, the second preset load threshold is reduced to the corresponding value using the first threshold adjustment coefficient of 0.95; If the vibration amplitude difference is greater than or equal to the first preset vibration amplitude difference and less than the second preset vibration amplitude difference of 0.2 mm, the second preset load threshold is reduced to the corresponding value using the second threshold adjustment coefficient of 0.88; If the vibration amplitude difference is greater than or equal to the second preset vibration amplitude difference, the second preset load threshold is reduced to the corresponding value using the third threshold adjustment coefficient of 0.82; The vibration amplitude difference is the difference between the vibration amplitude and the preset vibration amplitude.

[0047] In an embodiment of the present invention, the first preset vibration amplitude difference is taken as 0.1 mm, and the second preset vibration amplitude difference is taken as 0.2 mm. However, the above values are not limited thereto, and those skilled in the art can adjust the values according to actual needs.

[0048] Specifically, the first-level warning is a high-risk warning, and transportation needs to be immediately suspended and the load weight reduced; the second-level warning is a medium-risk warning, and transportation parameters need to be adjusted; the third-level warning is a low-risk warning, and the transportation status needs to be determined according to the actual environmental conditions.

[0049] Specifically, during the first-level warning, the load weight is reduced to 8t, but the above value is not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0050] Specifically, during the second-level warning, the adjusted transportation parameters such as transportation speed, transportation interval time, etc. are not specifically limited.

[0051] In the embodiment of the present invention, the initial transportation speed is taken as 1m / s, but the above value is not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0052] Specifically, during the third-level warning, the transportation status is determined according to the wind force level. Among them, if the wind force reaches level 8 or above, transportation is stopped; if the wind force level is greater than or equal to level 7 and less than level 8, the transportation speed is controlled within 0.5m / s; if the wind force level is less than level 7, normal transportation is carried out, and the transportation speed is not specifically limited.

[0053] So far, the technical solution of the present invention has been described in combination with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0054] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A material lifting and transportation overload protection warning system, characterized in that: include: A data acquisition module, which is used to monitor the load information of the transport equipment in real time, including a weight acquisition device for measuring the load weight, a current sensor for monitoring the motor current fluctuation, an acceleration sensor for monitoring the acceleration of the equipment startup, a vibration sensor for monitoring the vibration amplitude of the equipment, and a displacement sensor for obtaining the material transportation position; A control module connected to the data acquisition module, for determining whether the equipment is in an overload condition according to the dynamic load characteristic value obtained by the data acquisition module, and if an overload condition exists, a secondary determination is made according to the offset of the material reaching a preset point, or the acceleration of the equipment startup is reduced, and according to the result of the secondary determination that the equipment is in an overload condition, the cause of the overload is determined according to the current fluctuation value of the motor; The early warning module is connected to the control module and is used to send out an early warning signal and execute a corresponding early warning action according to the determination result of the control module.

2. The material lifting and transportation overload protection warning system according to claim 1 is characterized in that: The control module determines whether the device is in an overload condition according to the dynamic load characteristic value under the condition that the device load rate is less than the preset load rate, wherein: If the dynamic load characteristic value is less than the first preset load threshold, it is determined that the equipment is not overloaded and the transportation continues according to the current parameters; If the dynamic load characteristic value is greater than or equal to the first preset load threshold and less than the second preset load threshold, it is determined that the equipment is overloaded, and a second determination is made as to whether the equipment is overloaded based on the offset generated when the material reaches the preset point; If the dynamic load characteristic value is greater than or equal to the second preset load threshold, the equipment is determined to be overloaded and transportation is suspended, and the acceleration of the equipment when it starts is reduced according to the difference between the dynamic load characteristic value and the second preset load threshold.

3. The material lifting and transportation overload protection warning system according to claim 2 is characterized in that: The dynamic load characteristic value is determined by the dynamic load factor and the starting acceleration.

4. The material lifting and transportation overload protection warning system according to claim 2 is characterized in that: The control module starts a first-level warning under the condition that the equipment load rate is greater than or equal to the preset load rate.

5. The material lifting and transportation overload protection warning system according to claim 2 is characterized in that: The control module determines whether the equipment is overloaded based on the offset generated when the material reaches the preset point. If the offset is less than the first preset offset, it is determined that the equipment is not overloaded and the transportation continues according to the current parameters; If the offset is greater than or equal to the first preset offset and less than the second preset offset, the secondary determination device is overloaded, and the cause of the overload is determined based on the current fluctuation value of the motor; If the offset is greater than or equal to the second preset offset, the secondary determination device is overloaded and a secondary warning is initiated.

6. The material lifting and transportation overload protection warning system according to claim 2 is characterized in that: The control module is provided with several adjustment modes for the acceleration of the device startup, and each adjustment mode has a different reduction range for the acceleration.

7. The material lifting and transportation overload protection warning system according to claim 6 is characterized in that: The control module determines the cause of overload according to the current fluctuation value of the motor, wherein: If the current fluctuation value is less than the preset current fluctuation value, it is determined that the cause of the overload is uneven material distribution, and the motor speed is reduced according to the difference between the preset current fluctuation value and the current fluctuation value; If the current fluctuation value is greater than or equal to the preset current fluctuation value, it is determined that the cause of the overload is poor environmental conditions, and a third-level warning is initiated.

8. The material lifting and transportation overload protection warning system according to claim 6 is characterized in that: The control module determines the eligibility of the acceleration adjustment according to the vibration amplitude under the first preset condition, wherein: If the vibration amplitude is less than the preset vibration amplitude, it is determined that the acceleration adjustment is qualified; If the vibration amplitude is greater than or equal to the preset vibration amplitude, it is determined that the acceleration adjustment is unqualified, and the second preset load threshold is reduced according to the difference between the vibration amplitude and the preset vibration amplitude; The first preset condition is that the device completes the adjustment of acceleration.

9. The material lifting and transportation overload protection warning system according to claim 8 is characterized in that: The second preset load threshold is positively correlated with the vibration amplitude difference, wherein the vibration amplitude difference is the difference between the vibration amplitude and the preset vibration amplitude.

10. The material lifting and transportation overload protection warning system according to claim 1 is characterized in that: Level 1 warning is a high-risk warning, which requires immediate suspension of transportation and reduction of load weight; Level 2 warning is a medium-risk warning, which requires adjustment of transportation parameters; The third-level warning is a low-risk warning, and the transportation status needs to be determined based on the actual environmental conditions.

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