Traveling crane girder safety monitoring system and monitoring method

Abstract

The invention provides a crane girder safety monitoring system and method, and the system comprises a strain gauge sensor which is disposed on a crane girder. The data acquisition unit is in communication connection with the strain gauge sensor and is used for acquiring resistance information of the strain gauge sensor; the data acquisition unit is in communication connection with the central processing unit, and the central processing unit obtains the dependent variable of the crane girder based on the resistance information; the central processing unit is in communication connection with an alarm unit; the central processing unit compares the dependent variable of the traveling crane girder with a preset strain threshold value, and when the dependent variable of the traveling crane girder is larger than the strain threshold value, the central processing unit sends alarm information to the alarm unit. Dynamic stress monitoring and static stress monitoring can be carried out on the crane girder in real time, the stability of safe operation of the crane girder can be improved to a great extent, and unexpected safety accidents are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of crane equipment, and in particular to a crane beam safety monitoring system and a monitoring method. Background Art

[0002] Bridge cranes (cranes) play a vital role in the metallurgical production process. As a key load-bearing component of the entire crane, the girder bears the weight of the entire crane body and the transported items. Each transport will cause deformation, and safety accidents may occur when the transport is not standardized or exceeds the service life. Therefore, the girder is an important safety component of the crane and requires manual safety inspections at regular intervals. However, each inspection can only detect its dynamic elastic deformation response, and cannot detect its static deformation. In other words, it can only detect whether the deformation of the girder during the lifting process meets safety regulations. It cannot detect whether the deformation of the crane girder body caused by its own gravity after years of use meets safety regulations. Furthermore, it is impossible to perform real-time safety inspections on the crane girder. Summary of the Invention

[0003] In view of the shortcomings of the prior art described above, the purpose of the present invention is to provide a crane beam safety monitoring system and monitoring method, which can perform dynamic stress monitoring and static stress monitoring of the crane beam in real time, and can greatly improve the stability of the safe operation of the crane beam and reduce the occurrence of unexpected safety accidents.

[0004] To achieve the above-mentioned purpose and other related purposes, one aspect of the present invention provides a traveling beam safety monitoring system, comprising a strain gauge sensor, wherein the strain gauge sensor is arranged on the traveling beam; a data acquisition unit, which is communicatively connected to the strain gauge sensor, and the data acquisition unit is used to collect resistance information of the strain gauge sensor; a central processing unit, which is communicatively connected to the data acquisition unit, and the central processing unit derives the strain of the traveling beam based on the resistance information; an alarm unit, which is communicatively connected to the central processing unit; the central processing unit compares the strain of the traveling beam with a preset strain threshold value, and when the strain of the traveling beam is greater than the strain threshold value, the central processing unit sends an alarm message to the alarm unit.

[0005] Furthermore, it also includes a traveling winch, which is communicatively connected to the central processing unit. When the strain of the traveling beam is greater than the strain threshold, the central processing unit controls the operating speed of the traveling winch to decrease.

[0006] Furthermore, the resistance information of the strain gauge sensor collected by the data collection unit is a resistance change ΔR of the strain gauge sensor; and the central processing unit calculates the resistance information of the strain gauge sensor according to the formula: The strain of the traveling beam is calculated, where R is the initial resistance of the strain gauge sensor, K is the sensitivity coefficient of the strain gauge sensor, and ξ is the strain of the traveling beam.

[0007] Furthermore, the central processing unit is based on the formula: Adjust the running speed of the crane winch, where ξ is the strain of the crane beam, max is a preset strain threshold, S0 is the initial operating speed of the traveling hoist, and S is the operating speed of the traveling hoist after being reduced.

[0008] Furthermore, the central processing unit calculates the stress σ borne by the traveling beam according to the formula: σ=E*ξ, wherein E is the Young's modulus of the traveling beam and ξ is the strain of the traveling beam; and the central processing unit compares the stress σ borne by the traveling beam with the pre-set stress threshold σ max In contrast, when the stress σ borne by the traveling beam is greater than the stress threshold σ max When the central processing unit controls the crane winch to stop running.

[0009] Furthermore, a plurality of strain gauge sensors are provided on the traveling beam, and each of the strain gauge sensors is communicatively connected to the data acquisition unit.

[0010] As described above, the crane beam safety monitoring system of the present invention has the following beneficial effects: the crane beam safety monitoring system of the present invention can monitor the strain of the crane beam in real time by arranging a strain gauge sensor on the crane beam, that is, it can not only perform real-time dynamic deformation monitoring of the crane beam during the crane hoisting process, but also perform real-time static deformation monitoring of the crane beam when the crane is not hoisting. When the strain of the crane beam obtained in real time based on the real-time detection information of the strain gauge sensor by the central processor is greater than the preset strain threshold, the central processor will promptly send an alarm information to the alarm unit, so that the alarm unit will promptly send an alarm signal, thereby being able to promptly remind the operator to pay attention and conduct further inspections, thereby effectively avoiding the occurrence of unexpected safety accidents, and thus greatly improving the stability of the safe operation of the crane beam.

[0011] Another aspect of the present invention further provides a method for monitoring the safety of a traveling beam, comprising:

[0012] S1, the data acquisition unit collects the resistance information of the strain gauge sensor installed on the driving beam in real time;

[0013] S2. The central processing unit obtains the strain of the traveling beam in real time based on the resistance information;

[0014] S3, the central processing unit compares the real-time strain of the crane beam with a preset strain threshold;

[0015] S4. If the strain of the crane beam obtained in real time is greater than a preset strain threshold, the central processing unit sends an alarm message to the alarm unit and controls the operating speed of the crane winch to decrease;

[0016] S5. Determine whether the strain of the crane beam obtained in real time is greater than a preset strain threshold. If so, continue to reduce the operating speed of the crane winch.

[0017] Furthermore, in step S4, the central processing unit performs the following steps according to the formula Adjust the running speed of the crane winch, where ξ is the strain of the crane beam, max is a preset strain threshold, S0 is the initial operating speed of the traveling hoist, and S is the operating speed of the traveling hoist after being reduced.

[0018] Furthermore, the step 4 further includes: the central processing unit calculates the stress σ borne by the traveling beam according to the formula: σ = E * ξ, wherein E is the Young's modulus of the traveling beam, and ξ is the strain of the traveling beam; the central processing unit compares the stress σ borne by the traveling beam with a preset stress threshold σ max In contrast, when the stress σ borne by the traveling beam is greater than the stress threshold σ max When the central processing unit controls the crane winch to stop running.

[0019] The crane beam safety monitoring method of the present invention has the same beneficial effects as the above-mentioned crane beam safety monitoring system, so it will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Shown is a structural schematic diagram of the driving beam safety monitoring system provided by the present invention.

[0021] Figure 2 Shown is a flowchart of the crane beam safety monitoring method provided by the present invention.

[0022] Description of Reference Numerals

[0023] 10 Strain gauge sensors

[0024] 20 Data Acquisition Unit

[0025] 30 central processing units

[0026] 40 alarm units

[0027] 50 Crane winch

[0028] 100 Crane beam DETAILED DESCRIPTION

[0029] The following describes the embodiments of the present invention through specific examples. Those skilled in the art will readily understand the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the details in this specification may be modified or altered based on different viewpoints and applications without departing from the spirit of the present invention.

[0030] In the description of the present invention, it should be noted that, unless otherwise specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed or detachable connections, or integral connections; mechanical or electrical connections; direct connections or connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0031] In the description of the present invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," etc. used in the present invention to indicate orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are intended only to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as limiting the present invention. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be understood as indicating or implying relative importance.

[0032] See also Figures 1 to 2 It should be noted that the diagrams provided in this embodiment are merely schematic illustrations of the basic concept of the present invention. Therefore, the diagrams only show components related to the present invention and are not drawn according to the number, shape, and size of components in actual implementation. In actual implementation, the type, quantity, and proportion of each component may be changed arbitrarily, and the component layout may also be more complex.

[0033] One aspect of the present invention provides a driving beam safety monitoring system, such as Figure 1As shown, the traveling beam safety monitoring system includes a strain gauge sensor 10, a data acquisition unit 20, a central processing unit 30 and an alarm unit 40, wherein the strain sensor 10 is arranged on the traveling beam 100, and the data acquisition unit 20 is communicatively connected to the strain sensor 10. The data acquisition unit 20 is used to collect resistance information of the strain sensor 10. The data acquisition unit 20 is also communicatively connected to the central processing unit 30. The central processing unit 30 obtains the strain of the traveling beam based on the obtained resistance information. The alarm unit 40 is communicatively connected to the central processing unit 30. The central processing unit 30 compares the obtained strain of the traveling beam with a preset strain threshold. When the calculated strain of the traveling beam is greater than the strain threshold, the central processing unit 30 sends an alarm signal to the alarm unit 40.

[0034] The beneficial effects of the present invention are as follows: the crane beam safety monitoring system of the present invention is capable of real-time strain monitoring of the crane beam by arranging a strain gauge sensor 10 on the crane beam 100, that is, it is capable of real-time dynamic deformation monitoring of the crane beam during the crane hoisting process, and also real-time static deformation monitoring of the crane beam when the crane is not hoisting. When the strain of the crane beam obtained in real time by the central processing unit 30 based on the real-time detection information of the strain gauge sensor 10 (resistance information of the strain gauge sensor) is greater than a preset strain threshold, the central processing unit 30 will promptly send an alarm message to the alarm unit 40, so that the alarm unit 40 will promptly send an alarm signal, thereby being able to promptly remind the operator to pay attention and conduct further inspections, thereby effectively avoiding the occurrence of unexpected safety accidents, and thus greatly improving the stability of the safe operation of the crane beam.

[0035] Specifically, in this embodiment, the strain gauge sensor 10 can be attached and fixed to the maximum strain area of ​​the traveling beam. The maximum strain area of ​​the traveling beam can be confirmed in advance through finite element analysis and is usually located in the middle of the traveling beam. Preferably, the strain gauge sensor can be set in the middle area of ​​the traveling beam. When the traveling beam is deformed, the traveling beam will drive the strain gauge sensor to deform together. When the strain gauge sensor is deformed, its resistance will change accordingly. Therefore, in this embodiment, the resistance information of the strain gauge sensor collected by the data acquisition unit 20 is specifically the resistance change ΔR of the strain gauge sensor; the central processing unit 30 is based on the formula: The strain of the traveling beam is calculated, wherein K is the sensitivity coefficient of the strain gauge sensor, and ξ is the strain of the traveling beam.

[0036] Specifically, the strain gauge sensor 10 can be fixedly attached to the surface of the traveling beam by means of precision solder or high-strength adhesive. This high-stability installation method can improve the stability of the strain gauge sensor's installation on the traveling beam, that is, it can ensure the stability of the contact between the strain gauge sensor and the traveling beam for a long time, and improve the signal acquisition accuracy and stability of the strain gauge sensor.

[0037] Furthermore, in this embodiment, the strain gauge sensor is provided with an anti-corrosion coating and protective cover. This prevents interference with the strain gauge sensor caused by high temperature and high humidity environments, improving its anti-fouling and durability, and thereby increasing its service life. Strain gauge sensors installed via precision welding can also be sealed to prevent oxidation and corrosion, thereby improving their long-term stability. Furthermore, the strain gauge sensor 10 can communicate with the data acquisition unit 20 via wireless transmission, thereby reducing complex wiring layout and improving system maintenance convenience.

[0038] Furthermore, in order to improve the accuracy of the detection of the traveling beam, preferably, in this embodiment, a plurality of strain gauge sensors 10 are provided on the traveling beam, and each strain gauge sensor 10 is in communication connection with the data acquisition unit. Specifically, in addition to installing a strain gauge sensor in the middle area of ​​the traveling beam, at least two strain gauge sensors can be installed on the left and right sides of the traveling beam respectively. This multi-point arrangement can improve the monitoring coverage of the traveling beam and ensure the comprehensiveness and accuracy of data detection. As a preferred embodiment, Figure 1 As shown, a strain gauge sensor can be attached and installed at the middle of the traveling beam 100 at 45° and 135° directions respectively.

[0039] To further ensure the safety of the traveling beam during operation and increase its service life, in this embodiment, the central processing unit 30 is preferably in communication with the traveling winch 50. When the strain of the traveling beam exceeds a predetermined strain threshold, the central processing unit 30 controls the operating speed of the traveling winch 50 to decrease. With this arrangement, when the traveling beam strain is detected to be greater than the strain threshold, the traveling beam strain is reduced by appropriately reducing the operating speed, i.e., the lifting speed, of the winch 50. The central processing unit 30 then compares the changed traveling beam strain with the strain threshold. If the changed traveling beam strain is still greater than the strain threshold, the central processing unit further reduces the lifting speed of the winch 50 to further reduce the traveling beam strain. This cycle repeats until the traveling beam strain is less than or equal to the strain threshold, or until the traveling winch stops operating. This effectively limits beam deformation and prevents overload accidents.

[0040] Furthermore, in this embodiment, the central processing unit 30 may calculate the following formula: To adjust the operating speed of the crane winch, where ξ is the strain of the crane beam, max is the preset strain threshold, S0 is the initial operating speed of the traveling winch, and S is the operating speed of the traveling winch after it is reduced.

[0041] Furthermore, in order to further ensure the safety of the operation of the traveling beam and extend the service life of the traveling beam, preferably, in this embodiment, the central processing unit 30 can calculate the stress σ borne by the traveling beam according to the formula: σ = E * ξ, wherein E is the Young's modulus of the traveling beam, and ξ is the strain of the traveling beam; and the central processing unit compares the stress σ borne by the traveling beam with the pre-set stress threshold σ max In contrast, when the stress σ borne by the traveling beam is greater than the stress threshold σ max When the central processing unit 30 controls the crane hoist to stop running, the crane can avoid overloading of the crane beam, greatly ensure the safety of the operation, and extend the service life of the crane beam.

[0042] Another aspect of the present invention further provides a method for monitoring the safety of a traveling beam using the above-mentioned traveling beam safety monitoring system. Specifically, the traveling beam safety monitoring method comprises the following steps:

[0043] S1, the data acquisition unit collects the resistance information of the strain gauge sensor installed on the driving beam in real time;

[0044] When the traveling beam is deformed, the traveling beam will cause the strain gauge sensor to deform together with it. When the strain gauge sensor is deformed, its resistance will change accordingly. Therefore, in this embodiment, the resistance information of the strain gauge sensor 10 collected by the data acquisition unit 20 is the resistance change ΔR of the strain gauge sensor.

[0045] S2. The central processing unit obtains the strain of the traveling beam in real time based on the resistance information;

[0046] Specifically, in step S2, the central processing unit 30 may calculate the following formula: The strain of the traveling beam is calculated, where R is the initial resistance of the strain gauge sensor, K is the sensitivity coefficient of the strain gauge sensor, and ξ is the strain of the traveling beam.

[0047] S3, the central processing unit compares the real-time strain of the crane beam with a preset strain threshold;

[0048] S4. If the strain of the crane beam obtained in real time is greater than a preset strain threshold, the central processing unit sends an alarm message to the alarm unit and controls the operating speed of the crane winch to decrease;

[0049] Specifically, in step S3, the central processing unit 30 may calculate the following formula: Adjust the running speed of the crane winch, where ξ is the strain of the crane beam, max is a preset strain threshold, S0 is the initial operating speed of the traveling hoist, and S is the operating speed of the traveling hoist after being reduced.

[0050] Furthermore, in order to further ensure the safety of the operation of the traveling beam and extend the service life of the traveling beam, the step S4 further includes: the central processing unit 30 calculates the stress σ borne by the traveling beam according to the formula: σ = E * ξ, wherein E is the Young's modulus of the traveling beam and ξ is the strain of the traveling beam; the central processing unit compares the stress σ borne by the traveling beam with the pre-set stress threshold σ max In comparison, when the stress σ borne by the traveling beam is greater than the stress threshold σ max When the central processing unit 30 controls the crane winch to stop running.

[0051] S5. Determine whether the strain of the crane beam obtained in real time is greater than a preset strain threshold. If so, continue to reduce the operating speed of the crane winch.

[0052] The crane beam safety monitoring method of the present invention has the same beneficial effects as the above-mentioned crane beam safety monitoring system, so it will not be described in detail here.

[0053] Specifically, after the crane girder safety monitoring system is put into operation, it can collect sufficient data and analyze and establish an expert mathematical model based on big data. This enables real-time analysis, judgment, and prediction of the crane girder's health status, transforming "periodic maintenance" into "condition-based maintenance." Ultimately, the system can predict the crane girder's condition and remaining lifespan based on operating data, thus achieving "predictive maintenance."

[0054] In summary, the crane beam safety monitoring system and method of the present invention can effectively prevent unexpected safety accidents, providing effective protection for safe, reliable, and stable operation of cranes. Furthermore, they can effectively monitor and manage the health status of crane beams, reducing the workload of on-site inspection personnel. Therefore, the present invention effectively overcomes the shortcomings of existing technologies and has high industrial application value.

[0055] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A driving beam safety monitoring system, characterized in that: include: A strain gauge sensor, wherein the strain gauge sensor is arranged on the traveling beam; a data acquisition unit, communicatively connected to the strain gauge sensor, the data acquisition unit being configured to acquire resistance information of the strain gauge sensor; A central processing unit is in communication with the data acquisition unit, and the central processing unit derives the strain of the traveling beam based on the resistance information; an alarm unit, the alarm unit being in communication with the central processing unit; The central processing unit compares the strain of the traveling beam with a preset strain threshold value. When the strain of the traveling beam is greater than the strain threshold value, the central processing unit sends an alarm message to the alarm unit.

2. The vehicle beam safety monitoring system according to claim 1, characterized in that: It also includes a crane winch, which is communicatively connected to the central processing unit. When the strain of the crane beam is greater than the strain threshold, the central processing unit controls the operating speed of the crane winch to decrease.

3. The driving beam safety monitoring system according to claim 1, characterized in that: The resistance information of the strain gauge sensor collected by the data collection unit is the resistance change ΔR of the strain gauge sensor; the central processing unit calculates the resistance information of the strain gauge sensor according to the formula: The strain of the traveling beam is calculated, where R is the initial resistance of the strain gauge sensor, K is the sensitivity coefficient of the strain gauge sensor, and ξ is the strain of the traveling beam.

4. The driving beam safety monitoring system according to claim 2, characterized in that: The central processing unit is based on the formula: Adjust the running speed of the crane winch, where ξ is the strain of the crane beam, max is a preset strain threshold, S0 is the initial operating speed of the traveling hoist, and S is the operating speed of the traveling hoist after being reduced.

5. The driving beam safety monitoring system according to claim 2, characterized in that: The central processing unit calculates the stress σ borne by the traveling beam according to the formula: σ = E * ξ, wherein E is the Young's modulus of the traveling beam and ξ is the strain of the traveling beam; and the central processing unit compares the stress σ borne by the traveling beam with the pre-set stress threshold σ max In contrast, when the stress σ borne by the traveling beam is greater than the stress threshold σ max When the central processing unit controls the crane winch to stop running.

6. The vehicle beam safety monitoring system according to claim 1, characterized in that: A plurality of strain gauge sensors are provided on the traveling beam, and each of the strain gauge sensors is communicatively connected to the data acquisition unit.

7. A method for safety monitoring of a traveling beam using the traveling beam safety monitoring system according to any one of claims 1 to 6, characterized in that: The driving beam safety monitoring method specifically includes the following steps: S1, the data acquisition unit collects the resistance information of the strain gauge sensor installed on the driving beam in real time; S2. The central processing unit obtains the strain of the traveling beam in real time based on the resistance information; S3, the central processing unit compares the real-time strain of the crane beam with a preset strain threshold; S4. If the strain of the crane beam obtained in real time is greater than a preset strain threshold, the central processing unit sends an alarm message to the alarm unit and controls the operating speed of the crane winch to decrease; S5. Determine whether the strain of the crane beam obtained in real time is greater than a preset strain threshold. If so, continue to reduce the operating speed of the crane winch.

8. The method for monitoring the safety of a driving beam according to claim 7, characterized in that: In step S4, the central processing unit is based on the formula Adjust the running speed of the crane winch, where ξ is the strain of the crane beam, max is a preset strain threshold, S0 is the initial operating speed of the traveling hoist, and S is the operating speed of the traveling hoist after being reduced.

9. The method for monitoring the safety of a driving beam according to claim 7, characterized in that: The step 4 further includes: the central processing unit calculates the stress σ borne by the traveling beam according to the formula: σ = E * ξ, wherein E is the Young's modulus of the traveling beam and ξ is the strain of the traveling beam; the central processing unit compares the stress σ borne by the traveling beam with a preset stress threshold σ max In contrast, when the stress σ borne by the traveling beam is greater than the stress threshold σ max When the central processing unit controls the crane winch to stop running.

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