A portal crane service life estimation method and related device

Abstract

This application discloses a method and related device for estimating the life of a gantry crane, relating to the technical field of gantry cranes. The method comprises: obtaining known conditions of the gantry crane; the known conditions include: the gantry crane's maximum rated lifting capacity, the total lifting weight within a certain working cycle, and the total number of working cycles; determining an objective function and constraints based on the known conditions; solving the objective function to obtain a minimum value and a maximum value of the objective function; determining the number of equivalent full-load working cycles of the entire machine based on the minimum and maximum values of the objective function; and determining the remaining life of the gantry crane based on the number of equivalent full-load working cycles of the entire machine, the gantry crane's operating level, and the specified number of full-load working cycles of the crane. This application can solve the technical problem of estimating the remaining life of a gantry crane.

Description

Technical Field

[0001] The present application relates to the technical field of portal cranes, and in particular to a method for estimating the life of a portal crane and related devices. Background Art

[0002] In the relevant technology, the current damage condition of the gantry crane and the estimated remaining life can be determined based on the calculations in the relevant standards and specifications. However, due to the very complex usage of the gantry crane, it is generally impossible to record the lifting weight of each time under various working conditions. The results calculated only by the relevant methods have a large error compared with the actual usage of the equipment. The reliability of the determined crane remaining life estimation result is low. Therefore, there is still a technical problem of lack of a reliable method for estimating the remaining life of the gantry crane.

[0003] With respect to the technical problem of estimating the remaining life of gantry cranes in the above-mentioned related technologies, no effective solution has been proposed so far. Summary of the Invention

[0004] The purpose of this application is to provide a method for estimating the life of a portal crane and related devices, which can realize the remaining life estimation of the portal crane.

[0005] To achieve the above objectives, this application provides the following solutions.

[0006] In a first aspect, the present application provides a method for estimating the life of a portal crane as a whole, and the method for estimating the life of a portal crane as a whole comprises the following steps.

[0007] Acquire known conditions of the portal crane; the known conditions include: the maximum rated lifting weight of the portal crane, the total lifting weight in a certain working cycle, and the total number of working cycles.

[0008] Based on the known conditions, the objective function and constraint conditions are determined.

[0009] The objective function is solved to obtain a minimum value of the objective function and a maximum value of the objective function.

[0010] Based on the minimum value of the objective function and the maximum value of the objective function, the number of equivalent full-load working cycles of the whole machine is determined.

[0011] The remaining life of the portal crane is determined based on the equivalent full-load working cycle number of the whole machine, the working level of the portal crane and the specified full-load working cycle number of the crane.

[0012] Optionally, the expressions of the objective function and constraints are as follows.

[0013] .

[0014] .

[0015] .

[0016] .

[0017] in, is the objective function; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; is the maximum rated lifting load of the portal crane; It is the total lifting weight of the portal crane in a certain working cycle.

[0018] Optionally, solving the objective function to obtain the minimum value of the objective function specifically includes the following steps.

[0019] Construct the Lagrangian function.

[0020] The Lagrangian function is solved to obtain the minimum value of the objective function.

[0021] Optionally, the expression of the Lagrangian function is as follows.

[0022] .

[0023] in, is the Lagrangian function; is the Lagrange multiplier; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; It is the total lifting weight of the portal crane in a certain working cycle.

[0024] Optionally, the formula for solving the Lagrangian function is as follows.

[0025] .

[0026] .

[0027] .

[0028] in, is the Lagrangian function; is the Lagrange multiplier; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; It is the total lifting weight of the portal crane in a certain working cycle.

[0029] Optionally, solving the objective function to obtain the maximum value of the objective function specifically includes the following steps.

[0030] When the total number of working cycles of the portal crane is 2, the maximum value of the objective function is calculated.

[0031] When the total number of working cycles that have occurred for the portal crane is greater than 2, the generalization formula is determined based on the maximum value calculation formula of the objective function when the total number of working cycles that have occurred for the portal crane is 2.

[0032] Based on the generalized formula, the maximum value of the objective function is determined.

[0033] Optionally, the expression of the generalized formula is as follows.

[0034] .

[0035] .

[0036] .

[0037] in, is the maximum rated lifting load of the portal crane; The actual lifting load of the portal crane in each working cycle; is an intermediate variable; is the first given value, is an integer and ; is the second given value; The largest integer not greater than a certain number.

[0038] In a second aspect, the present application provides a computer device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement any of the above-described methods for estimating the life of a gantry crane.

[0039] In a third aspect, the present application provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements any of the above-mentioned methods for estimating the life of a gantry crane.

[0040] In a fourth aspect, the present application provides a computer program product, comprising a computer program, which, when executed by a processor, implements any of the above-mentioned methods for estimating the life of a gantry crane.

[0041] According to the specific embodiments provided in this application, this application discloses the following technical effects.

[0042] The present application provides a method and related device for estimating the life of a gantry crane. First, the known conditions of the gantry crane are obtained. The known conditions include: the maximum rated lifting weight of the gantry crane, the total lifting weight of a certain working cycle, and the total number of working cycles. This ensures that the relevant parameters of the gantry crane are accurate, thereby ensuring the scientificity and accuracy of subsequent steps, avoiding a series of misjudgments caused by initial data errors, and laying a solid foundation for accurately determining the remaining life of the crane. Secondly, based on the known conditions, the objective function and constraints are determined. The objective function is solved to obtain the minimum value and the maximum value of the objective function. By determining the objective function and the constraints, the core of the problem to be solved can be clarified, providing a clear direction and boundary for the subsequent solution process. After obtaining the minimum and maximum values of the objective function, the possible value range of the objective function under given conditions can be fully understood, providing key data support for the subsequent determination of the number of equivalent full-load working cycles of the whole machine, and helping to more accurately evaluate the working status and performance of the crane. Then, based on the minimum value of the objective function and the maximum value of the objective function, the number of equivalent full-load working cycles of the whole machine is determined; it can convert the actual complex and changeable working conditions into a relatively simple and unified measurement standard, facilitate the quantitative evaluation of the workload and wear degree of the gantry crane, and provide an easy-to-compare and analyze indicator for the subsequent determination of the remaining life. Finally, based on the number of equivalent full-load working cycles of the whole machine, the working level of the gantry crane and the specified number of full-load working cycles of the crane, the remaining life of the gantry crane can be accurately determined. On the one hand, it can help users reasonably arrange the use plan and maintenance strategy of the gantry crane to avoid equipment failure or even accidents caused by excessive use; on the other hand, it can also provide a scientific basis for the renovation of the gantry crane, improve the economic benefits and safety of equipment management and operation, and ensure the reliable operation of the gantry crane throughout its life cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0044] Figure 1 This is an application environment diagram of a method for estimating the life of a portal crane in one embodiment of the present application.

[0045] Figure 2A flowchart of a method for estimating the life of a portal crane provided in one embodiment of the present application.

[0046] Figure 3 A schematic diagram of the structure of a computer device provided in one embodiment of the present application. DETAILED DESCRIPTION

[0047] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0048] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0049] The method for estimating the life of a portal crane provided in the embodiment of the present application can be applied to Figure 1 In the application environment shown, terminal 102 communicates with server 104 via a network. A data storage system can store data that server 104 needs to process. The data storage system can be set up separately, integrated with server 104, or located in the cloud or on another server. Terminal 102 can send known conditions of the gantry crane to server 104. These known conditions include: the gantry crane's maximum rated lifting capacity, the total lifting weight within a certain working cycle, and the total number of working cycles. After receiving these known conditions, server 104 determines an objective function and constraints based on these known conditions. It solves the objective function to obtain the minimum and maximum values of the objective function. Based on the minimum and maximum values of the objective function, it determines the number of equivalent full-load working cycles of the entire machine. The remaining life of the gantry crane is determined based on the number of equivalent full-load working cycles of the entire machine, the gantry crane's operating level, and the specified number of full-load working cycles of the crane. Server 104 can provide feedback on the remaining life of the gantry crane to terminal 102. In addition, in some embodiments, the method for estimating the life of the entire gantry crane can also be implemented independently by the server 104 or the terminal 102. For example, the terminal 102 can directly estimate the life of the entire gantry crane based on the known conditions of the gantry crane, or the server 104 can obtain the known conditions of the gantry crane from the data storage system and estimate the life of the entire gantry crane based on the known conditions of the gantry crane.

[0050] The terminal 102 may be, but is not limited to, various desktop computers, laptop computers, smart phones, and tablet computers. The server 104 may be implemented as an independent server or a server cluster consisting of multiple servers, or a cloud server.

[0051] In an exemplary embodiment, Figure 2 As shown, a method for estimating the life of a portal crane is provided. The method is executed by a computer device, specifically a computer device such as a terminal or a server, or a terminal and a server. In the embodiment of the present application, the method is applied to Figure 1 The server 104 in the example is used for explanation, and the steps include the following steps S1 to S5.

[0052] S1: Obtain known conditions of the portal crane; the known conditions include: the maximum rated lifting weight of the portal crane, the total lifting weight in a certain working cycle, and the total number of working cycles.

[0053] S2: Based on the known conditions, determine the objective function and constraint conditions.

[0054] S3: Solve the objective function to obtain the minimum value and the maximum value of the objective function.

[0055] S4: Determine the number of equivalent full-load working cycles of the entire machine based on the minimum value of the objective function and the maximum value of the objective function.

[0056] S5: Determine the remaining life of the portal crane based on the equivalent full-load working cycle number of the whole machine, the working level of the portal crane and the specified full-load working cycle number of the crane.

[0057] By implementing steps S1 to S5, the lower and upper limits of the damage degree of the portal crane in a certain working cycle can be determined based on relevant information such as the total lifting load and the number of working cycles. Furthermore, the current overall damage status of the portal crane can be determined and the remaining lifespan can be predicted.

[0058] When the lifting weight and number of lifts of the gantry crane are known, the equivalent full-load working cycles of the whole machine can be estimated according to formula (1).

[0059] (1).

[0060] in, is the equivalent full-load working cycle number of the crane; is the magnification factor, taking into account the uncertainty of the recorded and estimated actual working loads of the crane; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; It is the maximum rated lifting load of the portal crane.

[0061] Due to the complex working conditions of gantry cranes, the types of goods lifted and the weight of each lift are not fixed. Generally, only the total lifting weight and the total number of working cycles in a certain working cycle can be given. Therefore, it is impossible to directly estimate the equivalent full-load working cycle number according to formula (1).

[0062] When direct estimation is not possible, the range of equivalent full-load working cycles is calculated based on limited working data, and the upper and lower limits of the number are given as a reference to estimate the remaining life of the portal crane. The specific method is shown below.

[0063] Given a portal crane with a maximum rated lifting load of Tons, total lifting weight in a certain working cycle Tons, total number of working cycles that the portal crane has undergone Secondly, estimating the upper and lower limits of the equivalent full-load working cycle number of this working period can be transformed into a conditional extreme value problem.

[0064] Assume that the actual lifting load of each working cycle is ton, .

[0065] The expressions of the objective function and constraints are as follows.

[0066] (2).

[0067] (3).

[0068] (4).

[0069] (5).

[0070] in, is the objective function, that is, The extreme value of .

[0071] As an optional implementation, in step S3, the objective function is solved to obtain the minimum value of the objective function, which specifically includes the following steps.

[0072] A1: Construct the Lagrangian function.

[0073] A2: Solve the Lagrangian function to obtain the minimum value of the objective function.

[0074] Specifically, the Lagrange multiplier is introduced , construct the Lagrangian function.

[0075] (6).

[0076] in, is the Lagrangian function.

[0077] right and Taking partial derivatives we get the following system of equations.

[0078] (7).

[0079] Solving the above system of equations yields .

[0080] (8).

[0081] That is, when the lifting weight is averaged each time, the objective function takes an extreme value, which is obviously the minimum value of the objective function. That is, the following formula holds.

[0082] (9).

[0083] As an optional implementation, in step S3, the objective function is solved to obtain the maximum value of the objective function, which specifically includes the following steps.

[0084] B1: When the total number of working cycles of the portal crane is 2, the maximum value of the objective function is calculated.

[0085] B2: When the total number of working cycles that have occurred for the portal crane is greater than 2, determine the generalized formula based on the maximum value calculation formula of the objective function when the total number of working cycles that have occurred for the portal crane is 2.

[0086] B3: Based on the generalized formula, determine the maximum value of the objective function.

[0087] Specifically, the discussion will be carried out in three steps.

[0088] a. When Sometimes, there are .

[0089] make , then the following formula holds.

[0090] (10).

[0091] (11).

[0092] Combining formula (10) and formula (11), we can get the following formula.

[0093] (12).

[0094] b. When When , refer to formula (12) and generalize it to assume that the following formula holds.

[0095] (13).

[0096] in, ; is the first given value, is an integer and , is the second given value; .

[0097] and The calculation formula is as follows.

[0098] (14).

[0099] (15).

[0100] in, The largest integer not greater than a certain number.

[0101] c. When, there is , making .

[0102] when When , the following formula holds.

[0103] (16).

[0104] when When , the following formula holds.

[0105] (17).

[0106] Combining formula (16) and formula (17), the maximum value of the objective function is , that is, the following formula holds.

[0107] (18).

[0108] in, , .

[0109] The upper and lower limits of the equivalent full-load working cycles of the crane with this working cycle are as follows.

[0110] , .

[0111] The present application also provides an application scenario, which applies the above-mentioned portal crane whole machine life estimation method. Specifically: The portal crane whole machine life estimation method provided in this embodiment can be applied in the portal crane whole machine life estimation scenario. The portal crane whole machine life estimation scenario includes: a data acquisition phase, an objective function and constraint condition determination phase, a solution phase, a whole machine equivalent full-load working cycle number determination phase, and a portal crane remaining life determination phase. First, the known conditions of the portal crane are obtained; the known conditions include: the maximum rated lifting weight of the portal crane, the total lifting weight of a certain working cycle, and the total number of working cycles; second, based on the known conditions, the objective function and constraint conditions are determined; the objective function is solved to obtain the minimum value and the maximum value of the objective function; then, based on the minimum value and the maximum value of the objective function, the whole machine equivalent full-load working cycle number is determined; finally, based on the whole machine equivalent full-load working cycle number, the working level of the portal crane, and the specified number of crane full-load working cycles, the remaining life of the portal crane is determined.

[0112] The following is an illustration using a specific evaluation case.

[0113] A 12t / 30m portal crane was manufactured in 1991, weighing approximately 260 tons and designed for a 15-year service life. Table 1 shows its operating information.

[0114] Table 1 Work record statistics

[0115]

[0116] (1) Design life of gantry crane.

[0117] The design life is determined when the crane is designed. It is related to the load state level and working level and should be provided by the manufacturer. According to GB / T20863.1-2021, when the working level A of the crane is known, the number of full-load working cycles of the crane specified in Table 2 should be calculated. Perform design calculations.

[0118] Table 2 Design values based on work level

[0119]

[0120] (2) Estimation of the lifting load and operating times of the gantry crane.

[0121] Based on the information provided in Table 1 and the calculation method for the upper and lower limits of the equivalent full-load working cycles of the gantry crane discussed above, calculate the load weight of each lift and the number of lifts of the corresponding weight.

[0122] a.Lower limit.

[0123] If the lifting weight is the same each time, then the lifting weight (t) is: .

[0124] b. Upper limit.

[0125] The maximum number of full-load operations is: ; The number of runs for other cases is: In other cases, the lifting weight (t) is: .

[0126] Table 3 Daily lifting load weight and corresponding operation times of portal crane

[0127]

[0128] (3) Estimation of equivalent full-load working cycles and remaining life.

[0129] According to the equipment working record information provided in Table 1, the total number of working cycles of the portal crane is: .

[0130] According to the calculation results provided in Table 3, the lower and upper limits of the equivalent full-load working cycle times are calculated as follows.

[0131] The lower limit of the equivalent working cycle number of the crane is estimated according to formula (1). Considering that the working cycle number is not automatically recorded, the actual working magnification factor in the formula is taken according to the provisions of Table 4. , then the lower limit is expressed as follows.

[0132] .

[0133] The upper limit is shown below.

[0134] .

[0135] According to Table 2, the working level is , load spectrum coefficient The number of full load working cycles is The estimated results show that the equivalent full-load working cycle of the crane is Next to The remaining life is between 0 and The design service life is approaching or exceeding the limit.

[0136] Table 4 Amplification factor

[0137]

[0138] Therefore, the following conclusions can be drawn: According to the operating data of the portal crane, the design life of the equipment is times, according to estimation, the equivalent full-load working cycle number is Next to The remaining life is between 0 and The gantry crane is approaching or exceeding its design life, and further inspection and evaluation of the equipment is required.

[0139] In an exemplary embodiment, a computer device is provided. The computer device may be a server or a terminal. The internal structure diagram thereof may be as follows: Figure 3 As shown. The computer device includes a processor, a memory, an input / output interface (I / O), and a communication interface. The processor, memory, and I / O interface are connected via a system bus, and the communication interface is connected to the system bus via the I / O interface. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system, a computer program, and a database. The internal memory provides an environment for the operation of the operating system and computer program in the non-volatile storage medium. The database of the computer device is used to store known conditions of the gantry crane. The I / O interface of the computer device is used to exchange information between the processor and an external device. The communication interface of the computer device is used to communicate with an external terminal via a network connection. When the computer program is executed by the processor, a method for estimating the service life of a gantry crane is implemented.

[0140] Those skilled in the art will understand that Figure 3 The structure shown in the figure is only a block diagram of a part of the structure related to the solution of the present application, and does not constitute a limitation on the computer device to which the solution of the present application is applied. The specific computer device may include more or fewer components than shown in the figure, or combine certain components, or have a different component arrangement.

[0141] In an exemplary embodiment, a computer device is further provided, including a memory and a processor. The memory stores a computer program, and the processor implements the above method embodiments when executing the computer program.

[0142] In an exemplary embodiment, a computer-readable storage medium is provided, storing a computer program, which implements the above-mentioned method embodiments when executed by a processor.

[0143] In an exemplary embodiment, a computer program product is provided, including a computer program. When the computer program is executed by a processor, the above method embodiments are implemented.

[0144] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, stored data, displayed data, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of relevant data must comply with relevant regulations.

[0145] Those skilled in the art will appreciate that all or part of the processes in the above-mentioned embodiments can be implemented by instructing the relevant hardware through a computer program. The computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the above-mentioned embodiments. In particular, any reference to memory, database, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM may be in various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM).

[0146] The databases involved in the various embodiments provided herein may include at least one of a relational database and a non-relational database. Non-relational databases may include, but are not limited to, distributed databases based on blockchains. The processors involved in the various embodiments provided herein may include, but are not limited to, general-purpose processors, central processing units, graphics processing units, digital signal processors, programmable logic units, data processing logic units based on quantum computing, and the like.

[0147] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0148] This document uses specific examples to illustrate the principles and implementation methods of this application. The description of the above examples is only intended to help understand the method and core concept of this application. At the same time, for those skilled in the art, based on the concept of this application, there may be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting this application.

Claims

1. A method for estimating the life of a portal crane, characterized in that: The method for estimating the life of the portal crane includes: Obtaining known conditions of the portal crane; the known conditions include: the maximum rated lifting weight of the portal crane, the total lifting weight in a certain working cycle, and the total number of working cycles; Based on the known conditions, determining the objective function and the constraint conditions; Solving the objective function to obtain a minimum value and a maximum value of the objective function; Determining the number of equivalent full-load working cycles of the entire machine based on the minimum value of the objective function and the maximum value of the objective function; Determining the remaining life of the portal crane based on the equivalent full-load working cycle number of the entire machine, the working class of the portal crane and the specified full-load working cycle number of the crane; Solving the objective function to obtain the maximum value of the objective function specifically includes: When the total number of working cycles of the portal crane is 2, the maximum value of the objective function is calculated; When the total number of working cycles of the portal crane is greater than 2, the generalized formula is determined based on the maximum value calculation formula of the objective function when the total number of working cycles of the portal crane is 2; Based on the generalized formula, determining the maximum value of the objective function; The expression of the generalized formula is: ； ； ； in, is the maximum rated lifting load of the portal crane; The actual lifting load of the portal crane in each working cycle; is an intermediate variable; is the first given value, is an integer and ; is the second given value; The largest integer not greater than a certain number.

2. The method for estimating the life of a portal crane according to claim 1, characterized in that: The expressions of the objective function and constraints are: ； ； ； ； in, is the objective function; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; is the maximum rated lifting load of the portal crane; It is the total lifting weight of the portal crane in a certain working cycle.

3. The method for estimating the service life of a portal crane according to claim 1, characterized in that: Solving the objective function to obtain the minimum value of the objective function specifically includes: Construct Lagrangian function; The Lagrangian function is solved to obtain the minimum value of the objective function.

4. The method for estimating the life of a portal crane according to claim 3, characterized in that: The expression of the Lagrangian function is: ； in, is the Lagrangian function; is the Lagrange multiplier; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; It is the total lifting weight of the portal crane in a certain working cycle.

5. The method for estimating the life of a portal crane according to claim 3, characterized in that: The formula for solving the Lagrangian function is: ； ； ； in, is the Lagrangian function; is the Lagrange multiplier; The actual lifting load of the portal crane in each working cycle; is the total number of working cycles that have occurred for the portal crane; It is the total lifting weight of the portal crane in a certain working cycle.

6. A computer device comprising: A memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method for estimating the service life of a portal crane according to any one of claims 1 to 5.

7. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the method for estimating the service life of a portal crane according to any one of claims 1 to 5 is implemented.

8. A computer program product comprising a computer program, characterized in that When the computer program is executed by a processor, the method for estimating the service life of a portal crane according to any one of claims 1 to 5 is implemented.

Images