Device for detecting crack and fatigue life of crane girder

Abstract

The invention discloses a device for detecting cracks and fatigue life of a main beam of a crane. The device mainly comprises an upper computer and a lower computer, the upper computer is a tablet computer or a computer with data receiving, storing, processing and controlling functions, the lower computer is a detection trolley with detecting, moving and cleaning functions, and the upper computer and the lower computer are communicated and controlled in a wireless mode; as the movable detection trolley is adopted, each position of the crane can be reached, the position of the crack can be accurately identified, and the efficiency is far higher than that of manual inspection; and the suspicious crack position is cleaned, so that the accuracy of fatigue crack identification is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of crane detection, and in particular to a device for detecting cracks and fatigue life of a crane main beam. Background Art

[0002] Existing crane structures, especially load-bearing structures like main beams, are prone to fatigue cracking due to repeated exposure to various loads over long periods of time. The propagation of these cracks not only shortens the service life of the main beam and other structures but can also pose safety hazards. Therefore, effectively detecting fatigue cracks and maximizing fatigue life in crane structures has become a pressing issue. By enabling real-time detection and timely treatment of structural fatigue cracks, and taking effective measures to slow the growth of fatigue cracks in the load-bearing structures, the risk of crane fatigue failure can be significantly reduced, the fatigue life of the structure can be extended, and crane safety can be improved.

[0003] After a crane is put into operation, crack inspections are primarily conducted by technicians. After climbing aboard the crane, technicians inspect each part of the crane one by one. This method provides a true reflection of the distribution of cracks within the crane.

[0004] The main drawbacks of manual inspection methods include: reliance on the experience and skills of the inspector, high labor intensity, safety hazards associated with crane access, low efficiency, inaccessible areas of the crane, and the inability to perform real-time inspections. Currently, there is no efficient equipment or method for real-time fatigue crack detection and fatigue life calculation. Summary of the Invention

[0005] The purpose of the present invention is to overcome the shortcomings of the above-mentioned background technology and provide a device and method for crane fatigue crack and fatigue life detection. The device is simple, convenient and easy to implement, and can well detect cracks in real time and discover fatigue hazards in time.

[0006] The technical solution of the present invention is: a device for detecting cracks and fatigue life of crane main beams, which is mainly composed of an upper computer and a lower computer; the upper computer is a tablet or computer with data receiving, storage, processing and control functions, and the lower computer is a detection trolley with detection, movement and cleaning functions. The upper computer and the lower computer are connected and controlled wirelessly.

[0007] The inspection vehicle is composed of a front vehicle and a rear vehicle, and the front vehicle is fixedly connected to the rear vehicle via a connecting device;

[0008] The front vehicle is composed of a driving wheel, a retractable cleaning device, a camera, an air suction cup II, a steel pull rope, and a battery. Four driving wheels are provided at the bottom of the front vehicle, and retractable cleaning devices are provided at both ends of the left side of the front vehicle. An air suction cup II is provided at the bottom of the front vehicle, and a camera and a connection point are provided on the air suction cup II. A connection device for connecting to the rear vehicle is provided at the right side of the front vehicle.

[0009] The rear vehicle consists of a drive wheel, a steel cable, a push rod, a reel, an electric motor, a battery, a ground mode signal light, a wall climbing mode signal light, an obstacle crossing mode signal light, and a charging port. A connection device for connecting to the front vehicle is located on the left side of the rear vehicle. Four drive wheels are located at the bottom. An air suction cup (I) is located on the left side of the rear vehicle's bottom, and a push rod is located on the air suction cup (I). A reel, an electric motor, and a battery are located on the right side of the rear vehicle's top. A steel cable is attached to the reel, one end of which is connected to the reel, and the other end passes through the push rod and is fixedly connected to the front vehicle's connection point. Three side-by-side mode signal lights are located on the right side of the rear vehicle: a ground mode signal light, a wall climbing mode signal light, and an obstacle crossing mode signal light. A convenient charging port is also provided for charging the batteries. When operated remotely from the ground, the mode signal light illuminates when a certain mode is selected.

[0010] The front car and the rear car are each equipped with a main control board and a drive board. The two main control boards can communicate with each other, and the main control boards are connected to the drive boards; the main control boards are connected to the APC220 wireless remote control module, etc.; the front car is also equipped with an ultrasonic obstacle avoidance module.

[0011] Compared with the prior art, the present invention has the following advantages:

[0012] 1. Accurate identification of cracks: Due to the use of a movable inspection trolley, it can reach various positions of the crane and accurately identify the location of the cracks, and the efficiency is much higher than manual inspection.

[0013] 2. Crack surface cleaning function: Since the movable inspection trolley is equipped with a cleaning device, the suspected crack position can be cleaned, which greatly improves the accuracy of crack identification.

[0014] 3. High passability: The inspection vehicle adopts a deformable front and rear vehicle structure, with ground mode, wall climbing mode, and obstacle crossing mode, allowing it to pass through complex areas. The lens adopts a retractable, bendable, and rotatable bracket form, which greatly increases the detection range. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the structure of the present invention;

[0016] Figure 2 Schematic diagram of the front vehicle structure of the present invention

[0017] Figure 3Schematic diagram of the rear vehicle structure of the present invention

[0018] Among them: 1. Retractable cleaning device, 2. Camera, 3. Steel pull rope, 4. Push rod, 5. Reel, 6. Motor, 7. Charging port, 8. Ground mode signal light, 9. Wall climbing mode signal light, 10. Obstacle crossing mode signal light, 11. Battery, 12. Air suction cup I, 13. Connecting device, 14. Connecting point, 15. Air suction cup II, 16. Driving wheel, 17. Main control board, 18. Driving board. DETAILED DESCRIPTION

[0019] This embodiment is a device for detecting cracks and fatigue life of crane main beams. The device is mainly composed of a host computer and a slave computer; the host computer is a tablet computer with data receiving, storage, processing and control functions, and the slave computer is a detection vehicle with detection, movement and cleaning functions. The host computer and the slave computer are connected and controlled wirelessly.

[0020] like Figure 1 、 Figure 2 、 Figure 3 As shown, the detection vehicle consists of a front vehicle and a rear vehicle, and the front vehicle is fixedly connected to the rear vehicle via a connecting device;

[0021] The front vehicle is composed of a driving wheel (16), a retractable cleaning device (1), a camera (2), and an air suction cup II (15). Four driving wheels (16) are provided at the bottom of the front vehicle. Retractable cleaning devices (1) are provided at both ends of the left side of the front vehicle. An air suction cup II (15) is provided at the bottom of the front vehicle. A camera (2) and a connection point (14) are provided on the air suction cup II (15). A connection device (13) for connecting to a rear vehicle is provided at the right side of the front vehicle.

[0022] The rear vehicle is composed of a driving wheel (16), a steel pull rope (3), a top rod (4), a reel (5), an electric motor (6), a battery (11), a ground mode signal light (8), a wall climbing mode signal light (9), an obstacle mode signal light (10), and a charging port (7). A connecting device (13) for connecting with the front vehicle is provided at the left side of the rear vehicle, four driving wheels (16) are provided at the bottom, an air suction cup I (12) is provided at the left side of the bottom of the rear vehicle, and a top rod (4) is provided on the air suction cup I (12). A reel (5), an electric motor (6) and a battery (11) are provided on the right side of the top of the rear vehicle. A steel pull rope (3) is provided on the reel (5). One end of the steel pull rope (3) is connected to the reel (5), and the other end passes through the top rod (4) and is fixedly connected to the connection point of the front vehicle. Three mode signal lights are arranged side by side on the right side of the rear vehicle, namely a ground mode signal light (8), a wall climbing mode signal light (9), and an obstacle crossing mode signal light (10). A convenient charging port for charging the battery is also provided.

[0023] The front vehicle and the rear vehicle are each provided with a main control board (17), a driving board (18) and a battery pack (11). The two main control boards can communicate with each other using an I2C bus wired along a connecting device 13. The main control board (17) is connected to the driving board (18); the main control board (17) is connected to a wireless remote control module; and the front vehicle is also provided with an ultrasonic obstacle avoidance module.

[0024] Install LabVIEW host computer software on a tablet or computer and design a LabVIEW front panel, i.e., an operation interface. The operator operates the LabVIEW host computer software and uses the APC220 serial port wireless module to send remote control instructions to the Arduino controller on the car. The Arduino controller reads the operation commands sent by the LabVIEW software and realizes the specified actions and behaviors in different modes through the driver board (18), including car movement, suction cup action, reel rotation, etc., so that the car performs the specified behavior actions.

[0025] The main program in LabVIEW consists of a sequence structure, a while loop, and an event structure. First, serial communication is initialized by setting the serial port number. Then, the program enters a while loop and event structure, continuously checking for events and executing them. The event structure includes "forward," "backward," "turn left," "turn right," "stop," "roller rotation," "roller stop," "suction cup action," and "suction cup stop." Finally, serial communication is closed. In the flowchart, the corresponding communication protocol is established, the serial port is configured, and different commands are sent through the serial port based on the key presses. The Arduino, the slave computer, receives the serial port receipt, parses the command code, and executes the corresponding command.

[0026] During the specific operation, the upper computer sets the detection trolley in ground mode, that is, when the main beam surface is horizontal, the ground mode signal light (8) lights up. The front car air suction cup II (15) and the rear car air suction cup I (12) are not started. The upper computer operation interface selects different buttons to allow the detection trolley to move forward, backward or turn. When the camera (2) is powered, it will shoot the surface cracks of the crane and transmit the video and photos to the upper computer. A manually adjustable retractable, rotatable and bendable bracket is used below the camera. According to the actual situation of the crane site, the height and angle of the bracket are manually adjusted before the inspection, and the shooting range is greatly increased compared to the fixed bracket. When the suspected crack position is covered with oil or other dirt, the retractable cleaning device (1) is operated on the upper computer operation interface, and the cleaning device lifting motor starts to work and lowers the device. The brush under the cleaning device contacts the suspected crack surface. The detection trolley moves repeatedly, driving the brush to repeatedly clean the surface. After cleaning is completed, the cleaning device is selected to end work on the upper computer operation interface, and the cleaning device lifting motor starts to rise and rotate to extend the cleaning device to the non-working position.

[0027] During the specific operation, when the host computer sets the detection vehicle to operate in the wall climbing mode, the wall climbing mode signal light (9) lights up. The motors of the front vehicle air suction cup II (15) and the rear vehicle air suction cup I (12) drive the internal fan impellers to rotate at high speed, causing air to be discharged at high speed, generating negative pressure between the bottom of the detection vehicle and the wall surface, so that the detection vehicle can be vertically adsorbed on the wall surface. The ultrasonic sensor of the obstacle avoidance module of the front vehicle can detect the distance to the surrounding obstacles and output pulses to the main control board (17) for processing. The motor (6) of the rear vehicle does not work, and the reel (5) does not rotate.

[0028] During the specific operation, when the trolley encounters an obstacle in front and needs to continue moving forward, the upper computer manually sets the detection trolley to the obstacle crossing mode, and the obstacle crossing mode signal light (10) lights up. The motor (6) of the rear car works, driving the reel (5) to rotate, and the steel pull rope (3) pulls up the front car through the top rod (4). The front car suction cup air suction cup II (15) stops working, and the detection trolley continues to move upward. When the front car is in a suitable position above the obstacle, the reel (5) rotates in the opposite direction, and the pull rope (3) lowers the front car through the top rod (4). The front car air suction cup II (15) resumes working, sucks the surface of the crane structure, and continues to move forward to drag the rear car up. The rear car air suction cup I (12) keeps working during the obstacle crossing process to ensure that the detection trolley does not fall. After crossing the obstacle and reaching the horizontal surface of the main beam, the front and rear car suction cups both stop working, and the detection trolley can operate in ground mode, and the ground mode signal light (8) lights up.

[0029] During the specific operation, the camera (2) will capture the surface cracks of the crane when it is powered on, and transmit the video and photos to the host computer. The size, distribution position and shooting time of the cracks are measured or recorded, and the fatigue crack position can be accurately located. The fatigue life calculation button is selected on the host computer operation interface, and relevant data such as the crack size is input. The fatigue life of the crane can be calculated according to the fatigue life calculation formula.

Claims

1. A device for detecting cracks and fatigue life of crane main beams, characterized by The device is mainly composed of an upper computer and a lower computer; the upper computer is a tablet or computer with data receiving, storage, processing and control functions, and the lower computer is a detection vehicle with detection, movement and cleaning functions. The upper computer and the lower computer are connected and controlled wirelessly.

2. The device for detecting cracks and fatigue life of crane main beams according to claim 1 is characterized in that The detection vehicle is composed of a front vehicle and a rear vehicle, and the front vehicle is fixedly connected to the rear vehicle through a connecting device; the front vehicle is composed of a driving wheel, a retractable cleaning device, a camera, and an air suction cup II. Four driving wheels are provided at the bottom of the front vehicle, and retractable cleaning devices are provided at both ends of the left side of the front vehicle. An air suction cup II is provided at the bottom of the front vehicle, and cameras and connection points are provided on the air suction cup II. A connection device for connecting to the rear vehicle is provided at the right side of the front vehicle; the rear vehicle is composed of a driving wheel, a steel pull rope, a top rod, a drum, an electric motor, a battery, a ground mode signal light, a wall climbing mode signal light, and an obstacle crossing mode signal light. The rear vehicle is composed of a signal light and a charging port. A connecting device connected to the front vehicle is provided at the left side of the rear vehicle, four driving wheels are provided at the bottom, an air suction cup I is provided at the left side of the bottom of the rear vehicle, a top rod is provided on the air suction cup I, a reel, an electric motor and a battery are provided at the right side of the top of the rear vehicle, a steel pull rope is provided on the reel, one end of the steel pull rope is connected to the reel, and the other end passes through the top rod and is fixedly connected to the connection point of the front vehicle; there are three side-by-side mode signal lights at the right side of the rear vehicle, which are a ground mode signal light, a wall climbing mode signal light and an obstacle crossing mode signal light, and a convenient charging port for charging the battery is also provided.

3. The device for detecting cracks and fatigue life of crane main beams according to claim 1 is characterized in that The front car and the rear car are respectively provided with a main control board and a driving board. The two main control boards can communicate with each other through the I2C bus. The main control boards are connected to the driving boards; the main control boards are connected to the wireless remote control modules.

4. The device for detecting cracks and fatigue life of crane main beams according to claim 1 is characterized in that The front vehicle is also provided with an ultrasonic obstacle avoidance module.

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