A material lifting and transporting overload protection and warning system

Abstract

The present invention relates to the technical field of overload warning, and in particular to an overload protection warning system for material lifting and transportation. It includes: a data acquisition module, which is used to monitor the load condition of the transportation equipment in real time, including a weight acquisition device, a current sensor, an acceleration sensor, a vibration sensor, and a displacement sensor; a control module, which is connected to the data acquisition module and is used to, when it is determined according to the dynamic load characteristic value that the equipment has an overload condition, re-determine whether the equipment has an overload condition according to the offset of the material reaching the preset point, or reduce the acceleration of the equipment startup, and when it is re-determined that the equipment has an overload condition, determine the overload cause according to the current fluctuation value of the motor; an early warning module, which is connected to the control module and is used to send out an early warning signal according to the determination result of the control module. The present invention improves the sensitivity of the overload protection warning system.

Description

Technical Field

[0001] The present invention relates to the technical field of overload warning, and particularly to an overload protection warning system for material hoisting and transportation. Background Art

[0002] In the field of material hoisting and transportation, 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 the main coal transportation device of 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 X minutes later; 6) Calculate the power value of the warning belt X minutes later, 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 an overload protection warning system for material hoisting and transportation 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 an overload protection warning system for material hoisting and transportation, including:

[0007] 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;

[0008] 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 to reduce the acceleration of the device startup, and according to the result of re-determining that the device is overloaded, to determine the overload cause according to the current fluctuation value of the motor.

[0009] An early warning module, which is connected to the control module, is used to send out an early warning signal according to the determination result of the control module and perform corresponding early warning actions.

[0010] 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

[0011] 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;

[0012] 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;

[0013] 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.

[0014] Further, the dynamic load characteristic value is jointly determined by the dynamic load coefficient and the startup acceleration.

[0015] 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.

[0016] Further, the control module re-determines whether the device is overloaded according to the offset generated when the material reaches the preset point, where

[0017] 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;

[0018] 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 overload cause is determined according to the current fluctuation value of the motor;

[0019] If the offset is greater than or equal to the second preset offset, it is determined that the secondary determination device is overloaded, and a secondary warning is initiated.

[0020] Further, the control module has several adjustment methods for the acceleration at which the device starts, and each adjustment method has a different reduction amplitude for the acceleration.

[0021] Further, the control module determines the cause of overload according to the current fluctuation value of the motor, where

[0022] If the current fluctuation value is less than the preset current fluctuation value, it is determined that the cause of 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;

[0023] If the current fluctuation value is greater than or equal to the preset current fluctuation value, it is determined that the cause of overload is poor environmental conditions, and a tertiary warning is initiated.

[0024] Further, the control module determines the qualification of acceleration adjustment according to the vibration amplitude under the first preset condition, where

[0025] If the vibration amplitude is less than the preset vibration amplitude, it is determined that the adjustment of the acceleration is qualified;

[0026] 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;

[0027] The first preset condition is that the device completes the adjustment of the acceleration.

[0028] 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.

[0029] Further, the primary warning is a high-risk warning, and the transportation needs to be immediately suspended and the load weight reduced; the secondary warning is a medium-risk warning, and the transportation parameters need to be adjusted; the tertiary warning is a low-risk warning, and the transportation status needs to be determined according to the actual environmental conditions.

[0030] Compared with the prior art, the beneficial effects of the present invention are that the present invention monitors the load condition of the transportation device in real time through the data acquisition module, 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.

[0031] Furthermore, the present invention sets up a three - level early warning mechanism, which can take corresponding measures according to different overload risk levels. This hierarchical early warning mechanism can effectively avoid false alarms and missed alarms, and improve the accuracy of early warning.

[0032] Furthermore, the present invention introduces dynamic load characteristic values to determine whether there is an overload situation in the equipment. It is jointly determined by the load weight and the dynamic load coefficient, which can more accurately reflect the actual load state of the equipment and avoid misjudgment caused by environmental interference or changes in the equipment operation state.

[0033] Furthermore, after initially determining that there is an overload situation in the equipment, the present invention makes a secondary determination based on the offset of the material reaching the preset point to further confirm the overload situation. The double - determination mechanism improves the reliability of the system and reduces the possibility of misjudgment.

[0034] Furthermore, the present invention analyzes the overload cause according to the current fluctuation value of the motor and takes corresponding measures, so as to solve the problem targeted.

[0035] Furthermore, through real - time monitoring and dynamic adjustment, the system of the present invention can effectively avoid damage to the equipment caused by overload or improper operation, extend the service life of the equipment, and ensure the safety of operators at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a schematic diagram of module connection of the overload protection early warning system for material lifting and transportation in the embodiment of the present invention;

[0037] Figure 2 It is a flowchart for determining whether there is an overload situation in the equipment in the embodiment of the present invention;

[0038] Figure 3 It is a flowchart for secondary determination of whether there is an overload situation in the equipment in the embodiment of the present invention;

[0039] Figure 4 It is a flowchart for determining the overload cause in the embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0040] 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.

[0041] 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.

[0042] It should be noted that the data in this embodiment are all obtained through comprehensive analysis and evaluation of the historical detection data in the three months before this detection by the present invention and the corresponding historical detection results. Those skilled in the art can understand that the determination method of the above single parameter by the present invention 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-item determination process through the obtained values.

[0043] Please refer to Figures 1 to 4 as shown, which are respectively the schematic diagram of module connection of the material lifting and transporting overload protection warning system in the embodiment of the present invention; the flowchart for determining whether the device is overloaded in the embodiment of the present invention; the flowchart for secondary determination of whether the device is overloaded in the embodiment of the present invention; the flowchart for determining the overload cause in the embodiment of the present invention.

[0044] The material lifting and transporting overload protection warning system in the embodiment of the present invention includes:

[0045] 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;

[0046] A control module, which is connected to the data acquisition module, and 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 overload condition, it is used to determine whether the device is overloaded again according to the offset of the material reaching the preset point, or to reduce the acceleration of the device startup, and according to the result of the secondary determination that the device is overloaded, to determine the overload cause according to the current fluctuation value of the motor;

[0047] A warning module, which is connected to the control module, and is used to send a warning signal according to the determination result of the control module and perform corresponding warning actions.

[0048] 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.

[0049] Specifically, 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 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 is not overloaded and continues to transport according to the current parameters;

[0050] 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 is overloaded, and whether the device is overloaded is re-determined according to the offset generated when the material reaches the preset point;

[0051] 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 at startup of the device is reduced according to the difference between the dynamic load characteristic value and the second preset load threshold.

[0052] Specifically, the load rate is the ratio of the current load to the preset load, and the current load is obtained by a weight acquisition device.

[0053] In the embodiment of the present invention, the value of the preset load is 10t, the value of the preset load rate is 80%, the value of the first preset load threshold is 1.2, and the value of the second preset load threshold 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.

[0054] Specifically, the dynamic load characteristic value is jointly determined by the dynamic load coefficient and the startup acceleration, and is calculated by the following formula, , where, , in the formula, K is the dynamic load coefficient, a is the startup 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 , is the vibration amplitude, is the vibration amplitude threshold, and is set , is the second weight coefficient, and is set , is the average current value, is the current threshold, and is set .

[0055] Specifically, the control module starts the first-level warning under the condition that the device load rate is greater than or equal to the preset load rate.

[0056] Specifically, the control module re-determines whether the device 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 re-determined that the device is not overloaded, and the transportation continues according to the current parameters;

[0057] If the offset is greater than or equal to the first preset offset and less than the second preset offset, it is determined that the secondary determination device is in an overload condition, and the overload cause is determined according to the current fluctuation value of the motor;

[0058] If the offset is greater than or equal to the second preset offset, it is determined that the secondary determination device is in an overload condition, and a secondary warning is started.

[0059] In the embodiment of the present invention, the value of the first preset offset is 10 mm, and the value of the second preset offset is 20 mm. However, the above values are not limited to this, and those skilled in the art can adjust the value according to actual needs.

[0060] Specifically, the offset is obtained by the displacement sensor in the data acquisition module.

[0061] Specifically, the control module has several adjustment methods for the acceleration at the start of the device, 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;

[0062] 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;

[0063] 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;

[0064] The dynamic load difference is the difference between the dynamic load characteristic value and the second preset load threshold.

[0065] In the embodiment of the present invention, the initial acceleration is set to 2 m / s 2 , the value of the first preset dynamic load difference is 0.2, and the value of the second preset dynamic load difference is 0.5. However, the above values are not limited to this, and those skilled in the art can adjust the value according to actual needs.

[0066] 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;

[0067] 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 third-level warning is started.

[0068] Specifically, the current fluctuation value is the standard deviation of the current for a preset sampling amount in a single transportation. The first sample is taken when the device is started, and then samples are taken at the same interval time. The specific interval time is not limited.

[0069] In the embodiment of the present invention, the preset current fluctuation value is taken as 0.5A, and the preset sampling amount is set to 20. However, the above values are not limited to this, and those skilled in the art can adjust these values according to actual needs.

[0070] 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 0.1A, the first speed adjustment coefficient of 0.96 is used to reduce the motor speed to the corresponding value;

[0071] 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 0.2A, the second speed adjustment coefficient of 0.90 is used to reduce the motor speed to the corresponding value;

[0072] If the current fluctuation difference is greater than or equal to the second preset current fluctuation difference, the third speed adjustment coefficient of 0.83 is used to reduce the motor speed to the corresponding value;

[0073] The difference between the preset current fluctuation value and the current fluctuation value.

[0074] In the embodiment of the present invention, the initial motor speed is set to 1000 r / min, the first preset current fluctuation difference is taken as 0.1A, and the second preset current fluctuation difference is taken as 0.2A. However, the above values are not limited to this, and those skilled in the art can adjust these values according to actual needs.

[0075] Specifically, the control module determines the qualification of the acceleration adjustment according to the vibration amplitude 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;

[0076] 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;

[0077] The first preset condition is that the device completes the acceleration adjustment.

[0078] In the embodiment of the present invention, the preset vibration amplitude is taken as 0.5 mm. However, the above value is not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0079] 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 first threshold adjustment coefficient of 0.95 is used to reduce the second preset load threshold to the corresponding value;

[0080] 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 threshold adjustment coefficient of 0.88 is used to reduce the second preset load threshold to the corresponding value;

[0081] If the vibration amplitude difference is greater than or equal to the second preset vibration amplitude difference, the third threshold adjustment coefficient of 0.82 is used to reduce the second preset load threshold to the corresponding value;

[0082] The vibration amplitude difference is the difference between the vibration amplitude and the preset vibration amplitude.

[0083] In the embodiment of the present invention, the value of the first preset vibration amplitude difference is 0.1 mm, and the value of the second preset vibration amplitude difference is 0.2 mm. However, the above values are not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0084] 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.

[0085] Specifically, during the first-level warning, the load weight is reduced to 8 t. However, the above value is not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0086] Specifically, during the second-level warning, the adjusted transportation parameters such as transportation speed, transportation interval time, etc. are not specifically limited.

[0087] In the embodiment of the present invention, the initial transportation speed is 1 m / s. However, the above value is not limited to this, and those skilled in the art can adjust this value according to actual needs.

[0088] 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 0.5 m / s; if the wind force level is less than level 7, normal transportation is carried out, and the transportation speed is not specifically limited.

[0089] So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easily understood by those skilled in the art 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.

[0090] 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 within the protection scope of the present invention.

Claims

1. A material lifting and transporting overload protection and warning system, characterized in that, 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 motor current fluctuation, an acceleration sensor for monitoring the equipment startup acceleration, a vibration sensor for monitoring the equipment 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 the equipment 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 determine whether the equipment is overloaded according to the offset of the material reaching the preset point, or to reduce the acceleration of the equipment startup, and according to the result of the secondary determination that the equipment is overloaded, to determine the overload cause according to the current fluctuation value of the motor; An early warning module, which is connected to the control module, and is used to send out an early warning signal according to the determination result of the control module and execute the corresponding early warning action; The dynamic load characteristic value is jointly determined by the dynamic load coefficient and the starting acceleration, and is calculated through 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, C1 is the first weight coefficient, A is the vibration amplitude, A0 is the vibration amplitude threshold, C2 is the second weight coefficient, I is the average current value, and I0 is the current threshold.

2. The material lifting and transporting overload protection warning system according to claim 1, characterized in that, The control module determines whether the equipment is overloaded according to the dynamic load characteristic value under the condition that the equipment 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 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 it is determined whether the equipment 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 equipment is overloaded, and the transportation is paused, and the acceleration of the equipment startup 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, characterized in that, The control module starts the first-level early warning under the condition that the equipment load rate is greater than or equal to the preset load rate.

4. The material hoisting and transportation overload protection warning system according to claim 2, characterized in that, The control module determines whether the equipment is overloaded according to 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 after secondary determination, 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 determined that the equipment is overloaded after secondary determination, and the overload cause 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 determined that the equipment is overloaded after secondary determination, and the second-level early warning is started.

5. The material lifting and transporting overload protection warning system according to claim 2, characterized in that The control module has several adjustment methods for the acceleration of the equipment startup, and the reduction amplitude of each adjustment method for the acceleration is different.

6. The material lifting and transporting overload protection and warning system according to claim 5, characterized in that, The control module determines the overload cause according to the current fluctuation value of the motor. 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 the third-level early warning is started.

7. The material hoisting and transportation overload protection and warning system according to claim 5, characterized in that, The control module determines the qualification of acceleration adjustment under a first preset condition, where if the vibration amplitude is less than a 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 acceleration adjustment.

8. The material lifting and transporting overload protection and warning system according to claim 7, characterized in that, 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.

9. The material hoisting and transportation overload protection warning system according to claim 1, characterized in that The first-level warning is a high-risk warning, and transportation needs to be suspended immediately 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.

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