Tower crane jacking fault identification and early warning device and method

Abstract

The invention discloses a tower crane jacking fault identification and early warning device which comprises a current detection module, the current detection module comprises a current transformer and a communication device, the current transformer is connected to the input end of a hydraulic pump station motor, and the current transformer sends data to a central control module through the communication device; the state detection module comprises a displacement sensor and a communication device, and the displacement sensor is installed on the jacking oil cylinder and sends data to the central control module through the communication device; the central control module is used for receiving the current data and the displacement data of the oil cylinder and judging whether a fault exists in the current operation process of the tower crane or not; and a man-machine interaction module. According to the method, the current transformer, the displacement sensor and the like are mounted on the tower crane, and fault recognition and early warning are performed on the current operation process of the tower crane according to the tower crane jacking fault recognition and early warning model, so that effective fault early warning of the operation process of the tower crane can be realized.

Description

Technical Field

[0001] This invention relates to the field of crane jacking fault identification. More specifically, this invention relates to a tower crane jacking fault identification and early warning device and method. Background Technology

[0002] Tower cranes are a type of mechanical equipment commonly used in building construction, bridge construction, highway construction, and other engineering projects. They are classified as high-risk special equipment. As the project progresses, tower cranes require installation and dismantling operations, including lifting and adding sections, and lowering sections. During these operations, safety accidents are prone to occur, causing significant casualties and economic losses. The main reasons are unsafe conditions of the tower crane equipment and improper behavior by the operators.

[0003] To reduce accidents involving tower cranes during installation and dismantling operations, regulatory authorities such as the Ministry of Housing and Urban-Rural Development and the State Administration for Quality Supervision, Inspection and Quarantine have successively issued standards, specifications, and notices related to tower crane installation and dismantling. Units at all levels have also adopted corresponding safety management measures. However, traditional monitoring methods mainly rely on manual observation, and managers can only know the progress of the operation after it is completed. This makes it impossible to achieve real-time remote monitoring and fault identification and early warning of the status of each process during installation and dismantling. Summary of the Invention

[0004] To achieve these objectives and other advantages according to the invention, in one aspect, a preferred embodiment of the invention provides a tower crane jacking fault identification and early warning device, wherein the tower crane is equipped with a hydraulic pump and a jacking cylinder, and the tower crane jacking fault identification and early warning device includes a current detection module, a central control module, a status detection module, and a human-machine interaction module: The current detection module consists of a current transformer and a communication device. The current transformer is connected to the input terminal of the hydraulic pump station motor and is used to collect the current data of the hydraulic pump and the duration of the current in real time. The current transformer sends the data to the central control module through the communication device. The status detection module consists of a displacement sensor and a communication device. The displacement sensor is installed on the lifting cylinder and is used to collect the cylinder displacement data of the lifting cylinder in real time and send it to the central control module through the communication device. The central control module receives the current data and duration transmitted by the current detection module; the central control module determines the current process of the tower crane based on the current data, duration and load conditions. Furthermore, the central control module also receives cylinder displacement data transmitted by the status detection module, and determines the current process of the tower crane based on the load conditions. The central control module continues to determine whether the judgment results of the two processes are consistent. If they are consistent, it is determined that there is no fault in the current operation process of the tower crane. If they are inconsistent, it is determined that there is a fault. The judgment result is then transmitted to the human-machine interaction module. The human-computer interaction module receives the judgment result from the central control module and displays it.

[0005] Preferably, it also includes an alarm module, which consists of an audible and visual alarm and a communication device, used to receive instructions from the central control module and to perform corresponding audible and visual alarms according to the instructions.

[0006] Preferably, the central control module preprocesses the current and displacement data using a sliding window mean filtering algorithm to improve data stability.

[0007] Preferably, the communication device between the current detection module and the status detection module supports dynamic adjustment of the transmission frequency.

[0008] On the other hand, the present invention also provides a method for identifying and warning of jacking faults in tower cranes, comprising the following steps: S1. Collect the current data and duration of the hydraulic pump station motor, as well as the cylinder displacement data of the lifting cylinder; S2. Collect the current data and duration of the tower crane during the no-load, no-load return, loaded return, and lifting processes, as well as the cylinder displacement data. S3. Perform sliding window mean filtering on the collected current and displacement data; S4. Establish a tower crane jacking fault identification and early warning model based on filtered current and displacement data; S5. Input the current data, duration, and cylinder displacement data of the current operation process into the tower crane jacking fault identification and early warning model. The tower crane jacking fault identification and early warning model determines which operation the tower crane is in based on the current data, duration, and load conditions. The central control module determines which operation the tower crane is in based on the cylinder displacement data and load conditions. If the outputs of the two models are consistent, no warning will be issued; otherwise, a fault warning will be triggered.

[0009] Preferably, in step S3, the collected current and displacement data are subjected to sliding window mean filtering, specifically using the following filtering formula: but The current and displacement data at time t are respectively In the formula, For data transmission frequency, Let be the filtered current value at time t. Let be the filtered displacement value at time t. for The current value at time [time]. for The displacement value at time t.

[0010] Preferably, the tower crane jacking fault identification and early warning model makes process judgments based on current data, duration, and the tower crane itself. The specific process is as follows: When the current value is a, the duration is T(a), and the load is 0, the tower crane is determined to be unloaded. When the current value is b, the duration is T(b), and the load is full, it is determined that the tower crane is in the lifting position; When the current value is c, the duration is T(c), and the load is 0, it is determined that the tower crane is in the no-load return stroke. When the current value is d, the duration is T(d), and the load is full, it is determined that the tower crane is in the return stroke under load. This invention has at least the following beneficial effects: By installing current transformers, displacement sensors, etc., on the tower crane and using a tower crane jacking fault identification and early warning model to identify and warn of faults in the current operation process of the tower crane, this invention can achieve effective fault early warning for the tower crane's operation process, with high accuracy and speed, significantly improving the safety and intelligence level of tower crane operation process identification.

[0011] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0012] Figure 1 This is a system component of the tower crane jacking fault identification and early warning device of the present invention.

[0013] Figure 2 This is a flowchart illustrating the early warning process of the tower crane jacking fault identification and early warning method of the present invention. Detailed Implementation

[0014] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0015] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious modifications will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0016] Those skilled in the art should understand that, in the disclosure of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the above terms should not be construed as limiting this invention.

[0017] It is understood that the term "a" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple, and the term "a" should not be understood as a limitation on the number.

[0018] like Figure 1-2 As shown, a preferred embodiment of the present invention provides a tower crane jacking fault identification and early warning device. The tower crane is equipped with a hydraulic pump and a jacking cylinder. The tower crane jacking fault identification and early warning device includes a current detection module, a central control module, a status detection module, and a human-machine interaction module. The current detection module consists of a current transformer and a communication device. The current transformer is connected to the input terminal of the hydraulic pump station motor and is used to collect the current data of the hydraulic pump in real time. The current transformer sends the data to the central control module through the communication device. The status detection module consists of a displacement sensor and a communication device. The displacement sensor is installed on the lifting cylinder and is used to collect the cylinder displacement data of the lifting cylinder in real time and send it to the central control module through the communication device. The central control module receives the current data and duration transmitted by the current detection module; the central control module determines the current process of the tower crane based on the current data, duration and load conditions. Furthermore, the central control module also receives cylinder displacement data transmitted by the status detection module, and determines the current process of the tower crane based on the load conditions. The central control module continues to determine whether the judgment results of the two processes are consistent. If they are consistent, it is determined that there is no fault in the current operation process of the tower crane. If they are inconsistent, it is determined that there is a fault. The judgment result is then transmitted to the human-machine interaction module. The human-computer interaction module receives the judgment result from the central control module and displays it.

[0019] The above implementation scheme employs two methods to determine the current operation of the tower crane, yielding two sets of results. The consistency of these two results is then further assessed. If they match, the operation is considered correct; otherwise, it is incorrect. For example, if the hydraulic cylinder reading gradually increases and the crane is fully loaded, it indicates the tower crane is in the lifting phase. However, if the current reading decreases and the crane is fully loaded, it indicates the crane is in the descent / return phase. Conflicting results from these two methods indicate a fault. This device can promptly detect and display faults in the operational process, providing operators with accurate fault warnings. This effectively improves the safety and reliability of tower crane lifting operations, preventing accidents caused by undetected faults and ensuring smooth construction progress.

[0020] Another technical solution also includes an alarm module, which consists of an audible and visual alarm and a communication device, used to receive instructions from the central control module and to issue corresponding audible and visual alarms according to the instructions.

[0021] In the above technical solution, the alarm module enables the central control module to quickly attract the operator's attention with an audible and visual alarm when a fault is detected. Compared with the human-machine interaction module alone, it can quickly convey fault information in complex construction environments, shorten the operator's reaction time, facilitate timely measures to deal with the fault, and further improve the safety and practicality of the device.

[0022] In another technical solution, the central control module preprocesses the current and displacement data using a sliding window mean filtering algorithm to improve data stability.

[0023] In the above technical solution, the central control module uses a sliding window mean filtering algorithm to preprocess the data, effectively reducing noise interference in current and displacement data and improving data stability. This makes fault judgment based on stable data more accurate, reduces the probability of false alarms and missed alarms, and enables the early warning device to work more reliably, providing stronger data support for the safe operation of tower cranes.

[0024] In another technical solution, the communication device between the current detection module and the status detection module supports dynamic adjustment of the transmission frequency.

[0025] In the above technical solution, the communication device between the current detection module and the status detection module supports dynamic adjustment of the transmission frequency, which can flexibly adjust the data transmission rate according to different jacking operation conditions. In conditions where data changes rapidly and real-time monitoring is required, the transmission frequency is increased to ensure data timeliness; when the operating conditions are stable, the transmission frequency is reduced to save resources, optimize data transmission efficiency, and enable the device to better adapt to different working environments.

[0026] On the other hand, another technical solution of the present invention also provides a method for identifying and warning of jacking faults in tower cranes, comprising the following steps: S1. Collect the current data and duration of the hydraulic pump station motor, as well as the cylinder displacement data of the lifting cylinder; S2. Collect the current data and duration of the tower crane during the no-load, no-load return, loaded return, and lifting processes, as well as the cylinder displacement data. S3. Perform sliding window mean filtering on the collected current and displacement data; S4. Establish a tower crane jacking fault identification and early warning model based on filtered current and displacement data; S5. Input the current data, duration, and cylinder displacement data of the current operation process into the tower crane jacking fault identification and early warning model. The tower crane jacking fault identification and early warning model determines which operation the tower crane is in based on the current data, duration, and load conditions. The central control module determines which operation the tower crane is in based on the cylinder displacement data and load conditions. If the outputs of the two models are consistent, no warning will be issued; otherwise, a fault warning will be triggered.

[0027] This method forms a complete fault identification and early warning system for tower crane jacking, from multi-condition data acquisition to the establishment of a fault identification and early warning model, and then to model-based fault judgment. It improves the accuracy of fault identification by determining whether to trigger an early warning based on the consistency of the comparison of current and displacement data, using the comparison results to support the judgment.

[0028] In another technical solution, the collected current and displacement data in S3 are subjected to sliding window mean filtering. The filtering formula is as follows: but The current and displacement data at time t are respectively In the formula, For data transmission frequency, Let be the filtered current value at time t. Let be the filtered displacement value at time t. for The current value at time [time]. for The displacement value at time t.

[0029] In another technical solution, the tower crane jacking fault identification and early warning model judges the tower crane's operation based on current data, duration, and cylinder displacement data, as shown in Table 1. The specific process is as follows: When the current value is a, the duration is T(a), and the load is 0, the tower crane is determined to be unloaded. When the current value is b, the duration is T(b), and the load is full, it is determined that the tower crane is in the lifting position; When the current value is c, the duration is T(c), and the load is the weight of the hydraulic cylinder and the lifting boom, it is determined that the tower crane is in the return stroke. When the current value is d, the duration is T(d), and the load is full, it is determined that the tower crane is in the return stroke.

[0030] Among them, a, b, c, d, T(a), T(b), T(c), and T(d) are all preset values ​​set in advance.

[0031] In the above technical solutions, the specific values ​​are set according to the actual situation. This application clearly provides the filtering formula, making the implementation of the sliding window mean filtering algorithm more specific and operable. Calculating and processing the current and displacement data based on this formula can accurately filter the data, ensuring that the filtered data more accurately reflects the actual working conditions. This lays a precise data foundation for subsequent fault diagnosis and model building, guaranteeing the accuracy of the entire early warning system.

[0032] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A tower crane jacking fault identification and early warning device, wherein the tower crane is equipped with a hydraulic pump and a jacking cylinder, characterized in that, The tower crane jacking fault identification and early warning device includes a current detection module, a central control module, a status detection module, and a human-machine interaction module. The current detection module consists of a current transformer and a communication device. The current transformer is connected to the input terminal of the hydraulic pump station motor and is used to collect the current data of the hydraulic pump and the duration of the current in real time. The current transformer sends the data to the central control module through the communication device. The status detection module consists of a displacement sensor and a communication device. The displacement sensor is installed on the lifting cylinder and is used to collect the cylinder displacement data of the lifting cylinder in real time and send it to the central control module through the communication device. The central control module receives the current data and duration transmitted by the current detection module; the central control module determines the current process of the tower crane based on the current data, duration and load conditions. Furthermore, the central control module also receives cylinder displacement data transmitted by the status detection module, and determines the current process of the tower crane based on the load conditions. The central control module continues to determine whether the judgment results of the two processes are consistent. If they are consistent, it is determined that there is no fault in the current operation process of the tower crane. If they are inconsistent, it is determined that there is a fault. The judgment result is then transmitted to the human-machine interaction module. The human-computer interaction module receives the judgment result from the central control module and displays it.

2. The tower crane jacking fault identification and early warning device according to claim 1, characterized in that, It also includes an alarm module, which consists of an audible and visual alarm and a communication device, used to receive instructions from the central control module and to issue corresponding audible and visual alarms according to the instructions.

3. The tower crane jacking fault identification and early warning device according to claim 1, characterized in that, The central control module preprocesses the current and displacement data using a sliding window mean filtering algorithm to improve data stability.

4. The tower crane jacking fault identification and early warning device according to claim 1, characterized in that, The communication device between the current detection module and the status detection module supports dynamic adjustment of the transmission frequency.

5. A method for identifying and warning of jacking faults in tower cranes, characterized in that, Includes the following steps: S1. Collect the current data and duration of the hydraulic pump station motor, as well as the cylinder displacement data of the lifting cylinder; S2. Collect the current data and duration of the tower crane during the no-load, no-load return, loaded return, and lifting processes, as well as the cylinder displacement data. S3. Perform sliding window mean filtering on the collected current and displacement data; S4. Establish a tower crane jacking fault identification and early warning model based on filtered current and displacement data; S5. Input the current data, duration, and cylinder displacement data of the current operation process into the tower crane jacking fault identification and early warning model. The tower crane jacking fault identification and early warning model determines which operation the tower crane is in based on the current data, duration, and load conditions. The central control module determines which operation the tower crane is in based on the cylinder displacement data and load conditions. If the outputs of the two models are consistent, no warning will be issued; otherwise, a fault warning will be triggered.

6. The tower crane jacking fault identification and early warning method according to claim 5, characterized in that, In S3, the collected current and displacement data are subjected to sliding window mean filtering, specifically using the following filtering formula: but The current and displacement data at time t are respectively 7. The tower crane jacking fault identification and early warning method according to claim 5, characterized in that, The tower crane jacking fault identification and early warning model makes process judgments based on current data, duration, and the tower crane's lifting operation. The specific process is as follows: When the current value is a, the duration is T(a), and the load is 0, the tower crane is determined to be unloaded. When the current value is b, the duration is T(b), and the load is full, it is determined that the tower crane is in the lifting position; When the current value is c, the duration is T(c), and the load is 0, it is determined that the tower crane is in the no-load return stroke. When the current value is d, the duration is T(d), and the load is full, it is determined that the tower crane is in the return stroke with load.

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