System for monitoring health state of elevator rope

Abstract

The invention discloses a system for monitoring the health state of an elevator rope, and the system achieves the real-time monitoring and early warning of the health state of the elevator rope through the real-time collection of multidirectional stress, the real-time calculation of the power of a motor main shaft, the synchronization of unified timestamps, the fusion of multi-source data and the state judgment based on historical samples. Compared with the mode of relying on manual inspection, potential abnormity is recognized in advance, the maintenance cost is reduced, the elevator operation safety and the maintenance efficiency are improved, the elevator operation safety is guaranteed, and meanwhile the maintenance efficiency and economical efficiency are remarkably improved. In addition, the embodiment of the invention provides a technical basis for constructing a steel wire rope state cloud platform to realize remote monitoring.

Description

Technical Field

[0001] This application relates to, but is not limited to, the field of elevator safety and maintenance technology, and in particular to a system for monitoring the health status of elevator ropes. Background Technology

[0002] Elevator ropes (including traction ropes, compensating ropes, and suspension ropes) are core load-bearing and power transmission components of elevator systems, and their health directly affects the elevator's operational safety and service life. Currently, the maintenance and condition assessment of elevator ropes mainly rely on traditional periodic manual maintenance. This model typically includes the following steps: maintenance personnel periodically arrive on-site to subjectively inspect the rope surface for defects such as broken wires, rust, wear, and deformation through visual observation and tactile examination, and measure changes in its diameter. This model has several major drawbacks: strong subjectivity and low reliability; periodic inspections without real-time early warning; low efficiency and high cost; and lack of in-depth data support.

[0003] How to monitor the overall health status of elevator ropes in real time, online, in multiple dimensions, and with high reliability, so as to significantly improve maintenance efficiency and economy while ensuring elevator operation safety, is a technical problem that urgently needs to be solved. Summary of the Invention

[0004] This application provides a system for monitoring the health status of elevator ropes, which can ensure the safe operation of elevators and significantly improve maintenance efficiency and economy.

[0005] This invention provides a system for monitoring the health status of elevator ropes, comprising: The first acquisition module includes multiple strain gauges installed on pulleys at both ends of the elevator rope to acquire multi-directional stress data of the elevator rope. The first processing module is used to perform analog-to-digital conversion on the obtained multi-dimensional stress data and add a unified timestamp, and then output the processed multi-dimensional stress data to the calculation module. The second acquisition module is used to interface with the elevator drive control system and acquire the motor spindle power signal in real time. The second processing module is used to add a unified timestamp to the obtained motor spindle power signal and then output it to the calculation module. The calculation module is used to perform time-series alignment of multi-directional stress data and motor spindle power signal according to a unified timestamp, and compare the aligned signal with historical samples in the database to determine the health status of the elevator rope.

[0006] In one exemplary instance, the multiple strain gauges include: three axial strain gauges disposed on the pulleys at each end of the elevator rope in an axial position, and three lateral strain gauges disposed in a lateral position.

[0007] In one exemplary instance, the three axial strain gauges are arranged at 120° intervals along the pulley axis.

[0008] In one exemplary instance, the three lateral strain gauges are arranged at 120° intervals along the side of the pulley.

[0009] In one exemplary instance, the first data processing module includes a digital-to-analog converter and a timestamp appending unit; wherein, A digital-to-analog converter is used to perform analog-to-digital conversion on the obtained multi-directional stress data; The timestamp appending unit is used to append a unified timestamp to the multi-directional stress data after the analog-to-digital conversion based on a unified time reference.

[0010] In one exemplary instance, the first processing module further includes one or any combination of the following: The data conversion unit is used to perform format conversion or encoding processing on the multi-directional stress data after the addition of a unified timestamp. A gain correction unit is used to perform gain compensation and zero-point correction on the multi-directional stress data after the additional unified timestamp or format conversion or encoding processing. The data formatting unit is used to structure the corrected multi-directional stress data according to a preset communication format.

[0011] In one exemplary instance, the second acquisition module includes a server, a Hall current sensor, and a power acquisition card; wherein, The servo is used to provide three-phase output terminals to the elevator drive control system and output three-phase voltage signals to drive the motor spindle on the three-phase output terminals. The Hall current sensor is installed in the three-phase current path of the motor spindle power supply circuit to collect current signals; The voltage input terminals of the power acquisition card are electrically connected to the three-phase output terminals of the servo to receive three-phase voltage signals; the current input terminals of the power acquisition card are connected to the signal output terminals of the Hall current sensor to receive current signals; the power acquisition card is used to calculate the power signal of the motor spindle in real time based on the three-phase voltage signal and the current signal, and output the calculated real-time power signal of the motor spindle to the second processing module.

[0012] In one exemplary instance, the calculation module compares the aligned signal with historical samples in the database to determine the health status of the elevator rope, including: The system identifies feature information characterizing the elevator rope's operating state from the aligned signal; compares the identified feature information with historical feature samples corresponding to different operating conditions pre-stored in the database, and judges the health status of the elevator rope based on the closest operating condition category obtained from the comparison.

[0013] In one exemplary instance, the computing module is further configured to: The aligned signal is filtered to reduce noise interference; then the feature information characterizing the elevator rope's running state is identified; and / or, The identified feature information is classified; the comparison at this time is to compare the classified feature information with historical samples in the database to determine the health status of the elevator rope.

[0014] In one exemplary instance, a display module is also included, for displaying the health status of the elevator rope output by the calculation module through a visual interface.

[0015] The system for monitoring the health status of elevator ropes provided in this application achieves real-time monitoring and early warning of the elevator rope's health status through real-time acquisition of multi-directional stress, real-time calculation of motor spindle power, unified timestamp synchronization, multi-source data fusion, and status determination based on historical samples. Compared to relying on manual inspections, this application identifies potential anomalies in advance, reduces maintenance costs, improves elevator operation safety and maintenance efficiency, and significantly enhances maintenance efficiency and economy. Furthermore, this application provides a technical foundation for building a wire rope status cloud platform for remote monitoring.

[0016] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the description, claims, and drawings. Attached Figure Description

[0017] The accompanying drawings are used to provide a further understanding of the technical solutions of this application and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of this application and do not constitute a limitation on the technical solutions of this application.

[0018] Figure 1 This is a schematic diagram of the composition structure of the system for monitoring the health status of elevator ropes in this embodiment of the application; Figure 2 This is a schematic diagram showing the installation of strain gauges on the elevator rope pulley in an embodiment of this application; Figure 3 This is a schematic diagram of the composition of the second acquisition module in the embodiments of this application. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in detail below with reference to the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be arbitrarily combined with each other.

[0020] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings, which illustrate embodiments of the present application. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this application will be thorough and complete.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0022] It is understood that the terms "first" and "second" used in this application are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0023] It is understood that the term "connection" in the following embodiments should be understood as "electrical connection," "communication connection," etc., if the connected circuits, modules, units, etc., have electrical signal or data transmission with each other.

[0024] When used herein, the singular forms of “a,” “an,” and “the” may also include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising / including” or “having,” etc., specify the presence of the stated features, wholes, steps, operations, components, parts, or combinations thereof, but do not preclude the possibility of the presence or addition of one or more other features, wholes, steps, operations, components, parts, or combinations thereof. Meanwhile, the term “and / or” as used in this specification includes any and all combinations of the associated listed items.

[0025] The steps illustrated in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowchart, in some cases the steps shown or described may be performed in a different order than that presented here.

[0026] Among related technologies, there are some experimental automated detection solutions, such as using a single eddy current detection technology to detect broken metal wires, or using simple vision sensors to capture images of the rope. However, these solutions still have significant limitations. For example, eddy current technology cannot effectively assess non-metallic inclusions, rope core damage, and lubrication status; while single vision solutions are easily affected by ambient light and oil contamination, and are difficult to detect internal rope damage, have a limited detection dimension, and suffer from high false alarm and false negative rates.

[0027] To monitor the overall health status of elevator ropes in real-time, online, multi-dimensionally, and with high reliability, and to achieve a fundamental shift from periodic preventative maintenance to condition-based predictive maintenance, thereby significantly improving maintenance efficiency and economy while ensuring elevator operational safety, this application provides a system for monitoring the health status of elevator ropes, such as... Figure 1 As shown, it may include: The first acquisition module includes multiple strain gauges installed on pulleys at both ends of the elevator rope, used to acquire multi-directional stress data of the elevator rope. The first processing module is used to perform analog-to-digital conversion on the obtained multi-dimensional stress data and add a unified timestamp, and then output the processed multi-dimensional stress data to the calculation module. The second acquisition module is used to interface with the elevator drive control system and acquire the motor spindle power signal in real time. The second processing module is used to add a unified timestamp to the obtained motor spindle power signal and then output it to the calculation module. The calculation module is used to perform time-series alignment of multi-directional stress data and motor spindle power signal according to a unified timestamp, and compare the aligned signal with historical samples in the database to determine the health status of the elevator rope.

[0028] The system for monitoring the health status of elevator ropes provided in this application achieves real-time monitoring and early warning of the elevator rope's health status through real-time acquisition of multi-directional stress, real-time calculation of motor spindle power, unified timestamp synchronization, multi-source data fusion, and status determination based on historical samples. Compared to relying on manual inspections, this application identifies potential anomalies in advance, reduces maintenance costs, improves elevator operation safety and maintenance efficiency, and significantly enhances maintenance efficiency and economy. Furthermore, this application provides a technical foundation for building a wire rope status cloud platform for remote monitoring.

[0029] In one exemplary instance, such as Figure 2As shown, taking an example where each pulley at each end of the elevator rope has three axial strain gauges in the axial position and three lateral strain gauges in the lateral position, a 2×3×3 multi-directional stress acquisition matrix is ​​formed to obtain the axial and lateral strain information of the elevator rope. In some other embodiments, four or more axial strain gauges can be installed on each pulley at the axial position. In some other embodiments, four or more lateral strain gauges can be installed on each pulley at the lateral position.

[0030] In one embodiment, three axial strain gauges are arranged at 120° intervals along the pulley axis on each end of the elevator rope. The three axial strain gauges are as follows: Figure 2 Strain gauges A1, A2, and A3 are shown in the figure.

[0031] In one embodiment, three lateral strain gauges are arranged at 120° intervals along the side of the pulley on each end of the elevator rope. The three lateral strain gauges are as follows: Figure 2 The strain gauges H1, H2, and H3 are shown in the figure.

[0032] In one exemplary instance, the first data processing module includes a digital-to-analog converter and a timestamp appending unit; wherein, A digital-to-analog converter is used to convert the acquired multi-dimensional stress data from analog to digital. The timestamp appending unit is used to append a unified timestamp to the multi-directional stress data after analog-to-digital conversion based on a unified time reference.

[0033] In one embodiment, the first processing module may further include one or any combination of the following: The data conversion unit is used to perform format conversion or encoding processing on the multi-directional stress data after attaching a unified timestamp; Gain correction unit is used to perform gain compensation and zero-point correction on multi-dimensional stress data after additional uniform timestamp or format conversion or encoding processing; The data formatting unit is used to structure the corrected multi-directional stress data according to a preset communication format.

[0034] In one exemplary instance, such as Figure 3 As shown, the second acquisition module may include a server 100, a Hall current sensor 200, and a power acquisition card 300; wherein, Servo unit 100 is used to provide three-phase output terminals U, V, and W to the elevator drive control system, and to output three-phase voltage signals for driving the motor spindle on the three-phase output terminals. .

[0035] The Hall current sensor 200 is installed in the three-phase current path of the motor spindle power supply circuit. Figure 3 The example shown illustrates the acquisition of two-phase current signals from a three-phase circuit. (The current of the other phase can be calculated from the balance relationship), and the collected two-phase current signals are output to the corresponding current input terminal of the power acquisition card 300.

[0036] The voltage input terminals of the power acquisition card 300 are electrically connected to the three-phase output terminals U, V, and W of the servo 100 to receive three-phase voltage signals. The current input terminals of the power acquisition card 300 are connected to the signal output terminals of the Hall current sensor 200 to receive current signals. The power acquisition card 300 is used to calculate the power signal of the motor spindle in real time based on the three-phase voltage signal and current signal, and output the calculated real-time motor spindle power signal to the second processing module.

[0037] In one exemplary instance, the calculation module compares the aligned signal with historical samples in the database to determine the health status of the elevator rope, including: The system identifies feature information that characterizes the elevator rope's operating status from the aligned signal; then compares the identified feature information with historical feature samples corresponding to different operating conditions pre-stored in the database, and judges the health status of the elevator rope based on the closest operating condition category obtained from the comparison.

[0038] In one exemplary instance, the computing module can also be used for: The aligned signal is filtered to reduce noise interference; then the feature information used to characterize the elevator rope's running state is identified.

[0039] In one exemplary instance, the computing module can also be used for: The identified features are classified; the comparison at this stage is to compare the classified features with historical samples in the database to determine the health status of the elevator rope.

[0040] In one exemplary instance, a display module is also included for displaying the health status of the elevator rope output by the calculation module through a visual interface.

[0041] In this embodiment, after the calculation module performs feature recognition on the time-aligned multi-directional stress data and power signal, it needs to classify the extracted features. Feature classification does not directly determine the health status of the elevator rope, but rather categorizes different features into several preset feature categories based on their attributes. For example, stress peak features, tension imbalance features, waveform impact features, or power anomaly features are classified into different categories. The purpose of feature classification is to organize and classify the features, so that different types of features can be mapped to corresponding historical working condition sample sets, facilitating subsequent comparison and analysis.

[0042] After completing feature classification, the calculation module compares the classified features with pre-stored historical operating condition samples in the database. These historical samples correspond to different elevator rope operating states, such as normal stress conditions, slight tension change conditions, wear trend conditions, abnormal impact conditions, or wire breakage risk conditions. By comparing the matching degree between the classified features and each historical sample, the calculation module can determine the operating condition category closest to the current elevator rope operating state. Based on this comparison result, the calculation module then judges the health status of the wire rope. For example, if it is closest to a normal operating condition sample, the wire rope is determined to be in a normal state; if it is close to a slightly abnormal operating condition sample, it is determined to be slightly abnormal; and if it corresponds to operating condition samples such as wear, impact, or signs of impending wire breakage, it is determined to be moderate or severe abnormal and an early warning is triggered.

[0043] In one embodiment, a 2×3×3 multi-directional stress acquisition matrix is ​​formed by arranging multiple strain gauges on the pulleys at both ends of the elevator rope. The motor spindle power is calculated in real time using the three-phase voltage signal output by the servo and the current signal acquired by the Hall current sensor, enabling the system to simultaneously obtain the stress state of the elevator rope and the power output information of the motor. By adding a unified timestamp based on the same time base to the stress and power data and achieving time alignment in the calculation module, the accuracy of multi-source signal fusion is significantly improved. Furthermore, the calculation module performs feature recognition and classification on the aligned signals and compares them with historical samples of different operating conditions in the database, thereby achieving real-time analysis and health status judgment of the elevator rope's operating state. In one embodiment, since the historical samples correspond to different wear levels, uneven tension, abnormal impact, or precursors to wire breakage, this embodiment of the application can promptly identify and generate early warning information when the elevator rope shows a potential deterioration trend.

[0044] This application embodiment, through real-time acquisition and multi-dimensional fusion of stress-power dual-channel signals, can construct a cloud-based full-cycle status monitoring system for elevator ropes. This allows maintenance personnel to obtain the real-time health status of the elevator ropes without relying on traditional manual periodic inspections. This enables early warning, reduces unnecessary component replacements, avoids sudden elevator shutdowns, significantly reduces maintenance costs, improves elevator operation and maintenance efficiency, and enhances elevator operational safety.

[0045] Although the embodiments disclosed in this application are as described above, the content described is merely for the purpose of understanding this application and is not intended to limit this application. Any person skilled in the art to which this application pertains may make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed in this application; however, the scope of patent protection of this application shall still be determined by the scope defined in the appended claims.

Claims

1. A system for implementing health monitoring of an elevator rope, characterized in that, The system comprises: a first acquisition module comprising a plurality of strain gauges respectively installed on pulleys at both ends of the elevator rope, for obtaining multi-directional stress data of the elevator rope; a first processing module for performing analog-digital conversion on the obtained multi-directional stress data and adding a unified timestamp, and outputting the processed multi-directional stress data to a calculation module; a second acquisition module for interfacing with an elevator drive control system and obtaining a motor main shaft power signal in real time; a second processing module for outputting the obtained motor main shaft power signal to the calculation module after adding a unified timestamp; a calculation module for performing time sequence alignment on the multi-directional stress data and the motor main shaft power signal according to the unified timestamp, and comparing the aligned signals with historical samples in a database to determine the health status of the elevator rope.

2. The system of claim 1, wherein, The plurality of strain gauges comprises three axial strain gauges arranged at axial positions on the pulleys at each end of the elevator rope, and three lateral strain gauges arranged at lateral positions on the pulleys.

3. The system of claim 2, wherein, The three axial strain gauges are arranged at intervals of 120° along the axial direction of the pulleys.

4. The system of claim 2, wherein, The three lateral strain gauges are arranged at intervals of 120° along the lateral direction of the pulleys.

5. The system of claim 1, wherein, The first data processing module comprises a digital-analog converter and a timestamp adding unit; wherein, the digital-analog converter is configured to perform analog-digital conversion on the obtained multi-directional stress data; the timestamp adding unit is configured to add a unified timestamp to the analog-digital converted multi-directional stress data based on a unified time reference.

6. The system of claim 5, wherein the first processing module further comprises one or any combination of the following: a data conversion unit configured to perform format conversion or encoding processing on the multi-directional stress data after adding the unified timestamp; a gain correction unit configured to perform gain compensation and zero point correction on the multi-directional stress data after adding the unified timestamp or format conversion or encoding processing; a data formatting unit configured to perform structured processing on the corrected multi-directional stress data according to a preset communication format.

7. The system of claim 1, wherein, The second acquisition module comprises a servo, a Hall current sensor, and a power acquisition card; wherein, the servo is configured to provide three-phase output terminals to the elevator drive control system and output three-phase voltage signals for driving the motor main shaft on the three-phase output terminals; the Hall current sensor is arranged in a three-phase current path of a motor main shaft power supply circuit to collect current signals; the voltage input terminals of the power acquisition card are electrically connected to the three-phase output terminals of the servo to receive the three-phase voltage signals; the current input terminals of the power acquisition card are connected to the signal output terminals of the Hall current sensor to receive the current signals; and the power acquisition card is configured to calculate the power signal of the motor main shaft in real time according to the three-phase voltage signals and the current signals, and output the calculated real-time motor main shaft power signal to the second processing module.

8. The system of claim 1, wherein, The comparison of the aligned signals with historical samples in the database to determine the health status of the elevator rope in the calculation module comprises: identifying feature information for representing the running state of the elevator rope from the aligned signals; and comparing the identified feature information with historical feature samples corresponding to different working conditions pre-stored in the database, and judging the health state of the elevator rope according to the closest working condition category obtained by the comparison.

9. The system of claim 8, wherein the computing module is further configured to: filter the aligned signals to reduce noise interference, and then identify the feature information for representing the running state of the elevator rope; and / or classify the identified feature information, and then compare the classified feature information with the historical samples in the database to judge the health state of the elevator rope.

10. The system of any one of claims 1-9, further comprising a display module configured to display the health state of the elevator rope output by the computing module through a visual interface.

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