Anchoring clip performance and hoist cylinder pressure maintaining detection system and method

Abstract

The application discloses an anchor clamp performance and hoister oil cylinder pressure maintaining detection system and method, and belongs to the technical field of hydraulic synchronous hoisting equipment detection. The system comprises a static and dynamic performance testing device, a dynamic load performance testing device, a pressure accessory system and a detection assembly. The pressure accessory system provides hydraulic power for the first two. The static and dynamic performance testing device realizes static and dynamic performance detection of the anchor clamp. The dynamic load performance testing device simulates dynamic load working condition detection. The detection assembly comprises multiple sensors, imaging and microscopic detection equipment and a data acquisition system, and realizes multi-dimensional data acquisition. The method comprises three detection links of static, dynamic and dynamic load, respectively detects the performance of the anchor clamp under different working conditions, simultaneously detects the pressure maintaining performance of the hoister oil cylinder, and evaluates the anchor clamp performance and the pressure maintaining performance of the hoister oil cylinder in combination with the detection data. The application is in line with the actual working condition, realizes accurate detection in multiple scenes, replaces experience judgment, and improves detection efficiency.

Description

Technical Field

[0001] This invention relates to the field of testing technology for hydraulic synchronous lifting equipment, and more specifically, to a testing system and method for the performance of anchor clamps and the pressure holding function of the lifting cylinder. Background Technology

[0002] Hydraulic synchronous integral lifting technology is a construction technology that uses computer-controlled multiple hydraulic lifters to achieve synchronous lifting of large steel structures. In recent years, it has been widely used in engineering fields such as bridges, connecting corridors, and super high-rise buildings. It is especially suitable for the integral hoisting of large-span and heavy structures, effectively solving the construction problems that traditional hoisting equipment cannot accomplish.

[0003] As the technology matures, it has overcome several technical bottlenecks in engineering practice. However, intermittent hydraulic synchronous lifting is still the dominant method in current engineering applications. In this mode, during load changes, the upper and lower anchors alternately tighten and loosen, causing the load to pause and restart, generating additional inertial forces. This not only reduces production efficiency but also causes intermittent fretting wear on the anchor clamps, a key component of the hydraulic lifter, gradually reducing their clamping performance and ultimately causing irreversible damage to system safety.

[0004] As the core load-bearing component of the lifting system, the performance of the anchor clamps of the synchronous lifting cylinder directly determines the system safety and is a core testing indicator for equipment maintenance. Based on the actual working conditions of the anchor clamps, performance testing needs to cover three major scenarios: static, dynamic, and external dynamic load. The static condition is when the anchor clamps are stationary and clamped, with no relative slippage or additional vibration, only subjected to constant clamping force and static friction. The dynamic condition is a cyclic clamping / unclamping state, accompanied by periodic slippage, alternating clamping force, and frictional fatigue. The dynamic load condition is when the anchor clamps are subjected to external periodic vibrations, impacts, and other additional loads in the stationary clamping state, with a constant clamping force but superimposed with inertial or shear forces.

[0005] Currently, anchor wrench performance testing faces challenges such as unclear standards, unscientific methods, and low efficiency. During maintenance and repair, workers often rely on experience to make rough judgments based on abnormal sounds and visual observation, failing to accurately identify microscopic damage and potential risks. This not only limits the standardized development of hydraulic synchronous lifting technology but also poses serious safety hazards to engineering construction. Therefore, there is an urgent need to develop a system and method for testing anchor wrench performance and lifting cylinder pressure holding performance that is tailored to the actual working conditions of anchor wrench projects, has a standardized testing process, and provides accurate results. This system and method should meet the testing needs of static, dynamic, and dynamic load scenarios, while shortening the testing process, clarifying testing standards, and enabling rapid and standardized testing of anchor wrench performance and lifting cylinder pressure holding performance. This would provide a scientific basis for the maintenance and repair of hydraulic synchronous lifting equipment and ensure the safety of engineering construction using hydraulic synchronous lifting technology. Summary of the Invention

[0006] This invention aims to address the problems of existing methods for testing the performance of anchor clamps and the pressure holding performance of lifting cylinders being crude, unable to cover multiple working conditions, and lacking sufficient testing accuracy. It provides a system and method for testing the performance of anchor clamps and the pressure holding performance of lifting cylinders. By simulating actual construction scenarios, it achieves accurate testing under static, dynamic, and dynamic load conditions, clarifies testing standards, simplifies the testing process, provides a scientific basis for the maintenance and repair of hydraulic synchronous lifting equipment, and ensures the construction safety of hydraulic synchronous lifting systems.

[0007] To achieve the above objectives, the present invention provides an anchor clamp performance and lifting cylinder pressure holding test system, including a static and dynamic performance testing device, a dynamic load performance testing device, a pressure accessory system and a testing component, wherein the pressure accessory system provides hydraulic power for the static and dynamic performance testing device and the dynamic load performance testing device;

[0008] The static and dynamic performance testing device includes a static and dynamic performance testing reaction frame fixed in the test area, two first synchronous lifters and a first set of steel strands. The two first synchronous lifters are respectively located on both sides of the static and dynamic performance testing reaction frame. A through channel is opened inside the static and dynamic performance testing reaction frame. A steel strand guide device is installed in the through channel. The first set of steel strands passes through the steel strand guide device, and both ends of the first set of steel strands are equipped with anchor clips. The anchor clips on both sides are respectively connected to the first synchronous lifter on the corresponding side through their bearing anchor plates.

[0009] The dynamic load performance testing device includes a dynamic load performance testing reaction frame, a second synchronous lifter, an excitation cylinder, and a second set of steel strands. The dynamic load performance testing reaction frame consists of a first reaction frame, a second reaction frame, and a third reaction frame located between the two. Each reaction frame is equipped with a steel strand guide device. The excitation cylinder is located between the first and third reaction frames, and its telescopic end is fixedly connected to the third reaction frame. The third reaction frame and the second reaction frame are fixedly connected by a connecting bracket. The second synchronous lifter is located on the outer side of the second reaction frame away from the third reaction frame. One end of the second set of steel strands is fixed to the test area, and the other end passes through the steel strand guide devices of each reaction frame in sequence and is then assembled with an anchor clamp. The anchor clamp is connected to the second synchronous lifter through its bearing anchor plate.

[0010] The detection components include a hydraulic pressure sensor, a dial gauge, a noise sensor, an industrial camera, an industrial endoscope, an electron microscope, and a data acquisition system. The data acquisition system is communicatively connected to the hydraulic pressure sensor, dial gauge, noise sensor, industrial endoscope, industrial camera, and electron microscope. Furthermore, each reaction frame, synchronous lifter, and anchor clamp is set up according to the actual construction scenario.

[0011] Preferably, the hydraulic pressure sensor is installed in the pressure accessory system and is used to detect the load applied by the first synchronous lifter cylinder, the second synchronous lifter cylinder and the excitation cylinder;

[0012] The dial gauges are respectively installed on the exposed end side of the anchor clamp to detect the relative slippage between the anchor clamp and the steel strand;

[0013] The noise sensors are respectively installed on the static and dynamic performance test reaction frame and the dynamic load performance test reaction frame, and are used to collect noise data during the loading, unloading and cyclic operation stages of the test process;

[0014] The industrial endoscope ring array is arranged around the anchor mechanism of the first synchronous lifter, and the displacement consistency of the anchor clamp group is detected through the gap between the end cap of the anchor mechanism and the cylinder.

[0015] The industrial camera and electron microscope are set up separately in the laboratory. The industrial camera is used to capture images of steel strand indentations and anchor tooth profiles, and the electron microscope is used to detect microscopic damage at the contact surface between the anchor clip and the steel strand.

[0016] Preferably, the static and dynamic performance testing reaction frame, the first reaction frame, the second reaction frame, and the third reaction frame are all rigid frame structures.

[0017] Preferably, the upper and lower ends of the third reaction frame are fixedly provided with limit rings, and the first reaction frame is fixedly provided with limit rods at positions corresponding to the limit rings. The ends of the limit rods away from the first reaction frame are inserted into the limit rings one by one to form a limit guide structure.

[0018] Preferably, the pressure accessory system includes four independent hydraulic components, which are respectively connected to the second synchronous lifter cylinder, the excitation cylinder and the two first synchronous lifter cylinders to provide independent hydraulic power to each cylinder.

[0019] In addition, the present invention also discloses a method for testing the performance of anchor clamps and the pressure holding performance of the lifting cylinder, which is implemented using the above-mentioned anchor clamp performance and lifting cylinder pressure holding test system. The method includes three testing steps: static testing, dynamic testing and dynamic load testing. By collecting test data in each step, the performance of the anchor clamps and the pressure holding performance of the lifting cylinder are comprehensively evaluated.

[0020] The static test is used to test the clamping performance of the anchor clip and the pressure holding performance after the lifting cylinder self-locks. By controlling the first synchronous lifting device to load, hold pressure and unload step by step, the test data is collected synchronously and micro and macro tests are completed. After each test, the anchor clip is replaced until the preset peak load test is completed.

[0021] The dynamic detection is used to detect the reliability and durability of the anchor clips' disengagement and the reliability of the anchor mechanism's movement, while also detecting the cyclic pressure holding performance of the lifting cylinder. By controlling one first synchronous lifting device to lock, and another first synchronous lifting device to alternately tighten and loosen the anchor and cyclically load, the detection data is collected in real time. Combined with endoscopic displacement detection and microscopic and macroscopic detection, the test ends when an abnormality occurs.

[0022] The dynamic load detection is used to detect the clamping performance of the anchor wedge under dynamic load conditions, and at the same time to detect the pressure holding stability of the lifting cylinder under dynamic load interference. By controlling the second synchronous lifting device to load and hold pressure, the periodic dynamic load is applied synchronously using the excitation cylinder, and the detection data, slippage amount and pressure holding status are collected in real time. If any abnormality occurs, the machine is immediately unloaded or stopped, and the anchor wedge is replaced before the subsequent detection is completed.

[0023] Preferably, the specific steps of the static detection are as follows:

[0024] The first synchronous lifter is controlled to load the load step by step according to the set load step. After each load reaches the preset load value, the pressure is maintained for a first set time, and then the unloading operation is performed.

[0025] Throughout the loading, pressure holding, and unloading process, load data is collected using the hydraulic pressure sensor, relative slippage data between the anchor clamp and the steel strand is collected using the dial indicator, and noise data is collected using the noise sensor. All data is transmitted to the data acquisition system for storage. Simultaneously, the load stability during the pressure holding process of the lifting cylinder is detected using the hydraulic pressure sensor. After each unloading stage, images of the steel strand indentation and anchor tooth profile are captured using an industrial camera. The anchor clamp is then disassembled, and its contact surface with the steel strand is cleaned with acetone. Microscopic inspection is then performed using an electron microscope. After that, a new anchor clamp is replaced, and the next stage of loading and testing continues until the preset peak load is completed.

[0026] Preferably, the dynamic detection step specifically includes:

[0027] Step 1: Control one of the first synchronous lifting devices to lock the first group of steel strands. After the other first synchronous lifting device completes the anchoring action, load it with the rated working load and the overload load exceeding the rated load by 10% in turn. After loading to the corresponding load value, hold the pressure for a preset time. Then control the cylinder of the first synchronous lifting device to unload and control its anchor mechanism to perform the anchor release action, so that the anchor clamp is separated from the anchor plate and the steel strands.

[0028] Step 2: Repeat the anchoring, loading, pressure holding, unloading, and anchor release process from Step 1. After each set number of executions, adjust the stroke of the first synchronous lifting cylinder to ensure that the engagement points of the anchor clamp and the steel strand are not concentrated in the same area.

[0029] Throughout the testing process, the hydraulic pressure sensor records load data in real time and monitors the pressure holding stability of the lifting cylinder. The noise sensor collects noise data. After each unloading, an industrial camera captures images of the steel strand indentation and the anchor tooth profile. After disassembling the anchor clamps and cleaning the contact surfaces with acetone, an electron microscope is used to inspect for microscopic damage. Displacement images of the anchor clamp group are acquired using an industrial endoscope arranged in a ring array. These images are transmitted to the analysis system via a data acquisition system. A deep learning model extracts the pixel coordinates of the anchor clamp group's center point in the images. By transforming the pixel coordinate system with the world coordinate system, the actual displacement difference between the anchor clamp groups is calculated. Based on these displacement differences, the number of anchor clamps with abnormal displacement is identified, and the corresponding load values ​​and test cycles are recorded.

[0030] If an abnormal noise is generated when the anchor wrench is unloaded and detached during the rated load test, the test for that load level should be terminated immediately and the total number of test rounds recorded. After replacing the anchor wrench with a new one, steps one and two should be repeated with an overload load. If an abnormal noise is detected during the overload load test, the total number of test rounds should be recorded and the dynamic test should be terminated.

[0031] Preferably, the specific steps of the dynamic load detection are as follows:

[0032] The second synchronous lifter is controlled to load to the rated load value, and after holding the load for a set time, the unloading operation is performed. During the holding load period, the excitation cylinder is controlled to apply a periodic dynamic load of a set size and frequency to the anchor clamp, with the duration consistent with the holding load duration. The dynamic load curve is recorded in real time by the hydraulic pressure sensor throughout the process, and the load stability during the holding pressure process of the second synchronous lifter cylinder is detected. The dynamic slippage fluctuation between the anchor clamp and the steel strand is detected by the dial indicator, where the dynamic slippage alarm threshold is 0.5mm. If the dynamic slippage exceeds the dynamic slippage alarm threshold or the load fluctuation during the holding pressure process of the lifter cylinder exceeds the set range, the pressure is immediately released and the machine is stopped. After unloading or stopping, the images of the steel strand indentation and the anchor tooth surface are taken by the industrial camera. The anchor clamp is disassembled and the contact surface is cleaned with acetone. The microscopic damage of the contact surface is then detected by the electron microscope.

[0033] Preferably, the performance of the anchor clamp and the pressure-holding performance of the lifting cylinder are evaluated based on the test data from the static test, dynamic test, and dynamic load test in the following manner:

[0034] Static inspection stage: Based on the images captured by the industrial camera and the microscopic damage detected by the electron microscope, the maximum load that is indistinguishable to the naked eye but poses a safety risk in the microscopic state is defined, and this load is taken as the theoretical value of the critical point for safe use of the anchor clamp; combined with the load data, pressure holding stability, slippage data and noise data during the inspection process, the clamping performance of the anchor clamp and the pressure holding performance of the lifting cylinder under static working conditions are comprehensively judged.

[0035] Dynamic detection phase: Based on the images captured by the industrial camera, the microscopic damage detected by the electron microscope, and the number of test rounds in which the anchoring noise occurred, the reliability and durability of the anchor wedge under dynamic working conditions are comprehensively judged; based on the displacement data collected by the industrial endoscope, the motion reliability of the anchor mechanism is evaluated; combined with the load fluctuation data during the pressure holding process of the lifting cylinder, the cyclic pressure holding performance of the lifting cylinder is evaluated.

[0036] Dynamic load testing stage: Based on the images captured by the industrial camera, the microscopic damage detected by the electron microscope, the dynamic load data and slippage data, the clamping performance and anti-interference stability of the anchor clamp under dynamic load conditions are evaluated; combined with the pressure holding fluctuation data of the lifting cylinder, the pressure holding stability of the lifting cylinder under dynamic load interference is evaluated.

[0037] Compared with the prior art, the present invention has at least one of the following advantages or beneficial effects:

[0038] I. Multi-condition testing closely matches reality, enabling simultaneous dual-performance testing: This invention integrates the testing of three working conditions—static, dynamic, and dynamic load—for the first time, accurately restoring the actual working state of the anchor wedges during hydraulic synchronous lifting construction. Simultaneously, it achieves simultaneous testing of the anchor wedge performance and the pressure-holding performance of the lifting cylinder. This solves the problems of traditional testing scenarios being limited, only able to test a single performance, and disconnected from actual on-site working conditions. The test results are more meaningful for engineering reference, providing a comprehensive basis for equipment maintenance and repair.

[0039] II. Multi-device collaborative detection enables dual macro- and micro-level screening: This invention employs multiple sensors, such as hydraulic sensors, dial gauges, and noise sensors, to collect quantitative data in real time. It combines macro-level imaging detection with macro-level damage detection using industrial cameras and micro-level damage detection using electron microscopes. Simultaneously, it utilizes industrial endoscopes to achieve visualized detection of the displacement consistency of anchor clamp groups, forming a multi-dimensional and complementary detection system that combines macro- and micro-level monitoring. This system completely replaces the traditional experience-based judgment mode, effectively avoids errors caused by human operation, and results in more scientific, accurate, and quantitative detection results.

[0040] III. Standardized and efficient testing process, suitable for batch maintenance: This invention optimizes and clarifies the testing steps for each working condition. Image acquisition and microscopic analysis can be completed simultaneously after each level or test. After replacing the anchor clamp, the next round of testing can be started quickly. The operation process is standardized, and operators can get started after simple training, which greatly improves the testing efficiency. It is very suitable for batch maintenance of anchor clamps in hydraulic lifting equipment that is returned to the factory.

[0041] IV. Stable and reliable equipment structure with high accuracy of testing: This invention adopts various reaction frames with rigid frame structures, combined with limit guide structures to restrict the movement direction of the excitation cylinders. At the same time, four sets of independent hydraulic components provide power to each cylinder, ensuring stability during the loading process and that the operation of each component does not interfere with each other. All testing equipment and components are simulated according to the actual working conditions of hydraulic synchronous lifting construction, which greatly improves the accuracy and reliability of the testing. The test results can truly reflect the actual working status of the equipment.

[0042] V. Clarify quantitative testing standards and promote the standardized development of the industry: This invention sets alarm thresholds for static and dynamic slippage, clarifies the definition method of the critical point for safe use of anchor wedges and the comprehensive evaluation system for the performance of anchor wedges and the pressure holding performance of lifting cylinders, fills the gap in relevant testing standards in the industry, provides important support for the further standardization and normalization of hydraulic synchronous lifting technology, and helps to improve the construction technology level and safety assurance capabilities of the entire industry. Attached Figure Description

[0043] The invention, its features, shape, and advantages will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings. Like reference numerals denote like parts throughout the drawings. The drawings are not drawn to scale; the emphasis is on illustrating the gist of the invention.

[0044] Figure 1 This is a perspective view of the static and dynamic performance testing device in an embodiment of the present invention;

[0045] Figure 2 This is a front view of the static and dynamic performance testing device in an embodiment of the present invention;

[0046] Figure 3 This is a perspective view of the dynamic load performance testing device in an embodiment of the present invention;

[0047] Figure 4 This is a front view of the dynamic load performance testing device in an embodiment of the present invention;

[0048] Among them, 1. Static and dynamic performance testing device; 11. Static and dynamic performance testing reaction frame; 12. First synchronous lifter; 13. Sensor arrangement frame; 14. First group of steel strands; 15. First steel strand guide device; 2. Dynamic load performance testing device; 21. First reaction frame; 22. Second reaction frame; 23. Third reaction frame; 24. Second synchronous lifter; 25. Second group of steel strands; 26. Connecting bracket; 27. Vibration cylinder; 28. Limiting rod; 29. ​​Limiting ring. Detailed Implementation

[0049] 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.

[0050] It should be noted that, unless otherwise specified, the test methods described in the following embodiments are all conventional methods, and the reagents and materials described are all commercially available unless otherwise specified. In the description of this invention, the terms "lateral", "longitudinal", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" 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, they should not be construed as limitations on this invention.

[0051] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but these are not intended to limit the scope of the invention.

[0052] Example 1:

[0053] like Figures 1-4 As shown in the figure, this embodiment discloses an anchor clamp performance and lifting cylinder pressure holding test system, which mainly consists of a static and dynamic performance testing device 1, a dynamic load performance testing device 2, a pressure accessory system and a testing component. The various parts work together to realize the multi-condition performance test of the anchor clamp.

[0054] I. Static and Dynamic Performance Testing Device

[0055] The static and dynamic performance testing device includes a static and dynamic performance testing reaction frame 11 fixed in the test area, two first synchronous lifters 12, and a first set of steel strands 14. The two first synchronous lifters 12 are respectively arranged on both sides of the static and dynamic performance testing reaction frame 11. The static and dynamic performance testing reaction frame 11 has a through channel inside, and a first steel strand guide device 15 is installed in the through channel to ensure that the steel strands are always kept horizontal and to avoid interference or entanglement during the testing process.

[0056] The first set of steel strands 14 are threaded through the first steel strand guide device 15. Both ends of the steel strands are equipped with anchor clips. The anchor clips on both sides are connected to the corresponding first synchronous lifter 12 through their own bearing anchor plates to achieve stable load transmission.

[0057] II. Dynamic Load Performance Testing Device

[0058] The dynamic load performance testing device 2 includes a dynamic load performance testing reaction frame, a second synchronous lifter 24, an excitation cylinder 27, and a second set of steel strands 25. The dynamic load performance testing reaction frame is composed of a first reaction frame 21, a second reaction frame 22, and a third reaction frame 23 located between the two. The first reaction frame 21, the second reaction frame 22, and the third reaction frame 23 are all equipped with a second steel strand guide device. A set of excitation cylinders 27 (including two excitation cylinders 27) is set between the first reaction frame 21 and the third reaction frame 23. The telescopic end of the excitation cylinder 27 is fixedly connected to the third reaction frame 23. The third reaction frame 23 is fixed to the second reaction frame 22 as a whole through the connecting bracket 26. The second synchronous lifter 24 is located on the outside of the second reaction frame 22 away from the third reaction frame 23. One end of the second set of steel strands 25 is fixed to the test area by a ground anchor, and the other end passes through the second steel strand guide device inside the first reaction frame 21, the third reaction frame 23, and the second reaction frame 22 in sequence before being assembled onto the anchor clamp. The anchor clamp is connected to the second synchronous lifter 24 through its own bearing anchor plate. It should be noted that the anchor clamps used in the dynamic load performance testing device 2 and the static and dynamic performance testing device 1 are of the same specification to ensure the consistency of the test objects.

[0059] III. Detection Components

[0060] The testing components include a hydraulic pressure sensor, dial gauge, noise sensor, industrial camera, industrial endoscope, electron microscope, and data acquisition system. The data acquisition system is communicatively connected to the hydraulic pressure sensor, dial gauge, noise sensor, industrial endoscope, industrial camera, and electron microscope to collect and store various types of testing data in real time. Furthermore, each reaction frame, the first and second synchronous lifters, and the anchor clamps are set according to the dimensions, installation methods, and load conditions of the actual construction scenario to ensure that the testing results are consistent with the actual project.

[0061] The installation and functions of each testing component are as follows: The hydraulic pressure sensor is installed in the pressure accessory system to detect the load applied by the first synchronous lifter cylinder, the second synchronous lifter cylinder, and the excitation cylinder 27 (i.e., each hydraulic component connected to the cylinder is equipped with a hydraulic pressure sensor); dial indicators are respectively installed on the exposed end sides of the anchor clamps (i.e., dial indicators are installed on the exposed end sides of the anchor clamps in both the static / dynamic performance testing device 1 and the dynamic load performance testing device 2) to detect the relative slippage between the anchor clamps and the steel strand; noise sensors are respectively installed on the static / dynamic performance testing reaction frame 11 and the dynamic load performance testing device 2. Noise sensors are installed on the test reaction frames (i.e., both the static and dynamic performance test reaction frames 11 and the dynamic load performance test reaction frames) to collect noise data during the loading, unloading, and cyclic operation phases of the test. Six industrial endoscopes are arranged in a ring array around the anchor mechanism of the first synchronous lifter to detect the displacement consistency of the anchor clamp group through the gap between the end cap and the cylinder of the anchor mechanism. Industrial cameras and electron microscopes are set up separately in the laboratory. The industrial cameras are used to capture images of the steel strand indentation and the tooth profile of the anchor, and the electron microscopes are used to detect the microscopic damage of the contact surface between the anchor clamp and the steel strand.

[0062] IV. Pressure accessory system and other structures

[0063] The pressure accessory system includes four independent hydraulic components, which are connected one-to-one with the second synchronous lift cylinder, the excitation cylinder 27, and the two first synchronous lift cylinders, respectively, to provide independent and stable hydraulic power for each actuator and ensure the accuracy of cylinder action and load detection.

[0064] In this embodiment, the aforementioned static and dynamic performance testing reaction frames 11, 21, 22, and 23 all adopt rigid frame structures to ensure stable load bearing without plastic deformation during the testing process. The static and dynamic performance testing reaction frame 11 is equipped with a sensor arrangement frame 13, on which the noise sensor of the static and dynamic performance testing device 1 is mounted, ensuring accurate installation and stable signal. The sensor of the dynamic load performance testing device 2 can be directly mounted on the reaction frame. Limiting rings 29 are fixedly installed at both the upper and lower ends of the third reaction frame 23. Limiting rods 28 are fixedly installed on the first reaction frame 21 at positions corresponding to the limiting rings 29. The ends of the limiting rods 28 away from the first reaction frame 21 pass through the limiting rings 29, forming a limiting and guiding structure to restrict the movement trajectory of the third reaction frame 23 and prevent deviation during excitation.

[0065] The following requirements must be followed during the assembly of the above-mentioned anchor clamp performance and lifting cylinder pressure holding test system to ensure test accuracy:

[0066] (1) The static and dynamic performance test reaction frame 11 must be firmly fixed. Its design dimensions and structural strength are proportionally reduced according to the actual maximum load during construction. The installation position is accurately measured to ensure that the horizontality and verticality meet the design requirements and avoid installation errors affecting the test results. The two first synchronous lifters 12 are firmly connected to the static and dynamic performance test reaction frame 11, the hydraulic interface is well sealed, and the installation position is adjusted to ensure that the connection point with the first group of steel strands 14 is stable and the load is evenly distributed.

[0067] (2) The steel strand guiding device consists of multiple guide wheels and fixed brackets. During installation, the guide wheels must be kept clean and lubricated to reduce friction with the steel strand. At the same time, the installation position should be adjusted to ensure that the steel strand passes horizontally without deviation.

[0068] (3) The dynamic load performance test reaction frame is horizontally fixed and the installation foundation is reinforced. Its relative position with the static and dynamic performance test reaction frame 11 meets the design requirements to avoid interference during dynamic testing. The excitation cylinder 27 is installed in the reserved position of the reaction frame, with a firm connection and sealed interface. The installation position is precisely adjusted to ensure uniform load application.

[0069] (4) The hydraulic pump, hydraulic tank and hydraulic pipeline of the pressure accessory system are installed in the correct direction, the oil tank is clean and sealed, and the pipeline connection is sealed and unobstructed to prevent hydraulic oil leakage or contamination.

[0070] (5) The installation position and direction of each sensor are accurate, and the distance and angle between the sensor and the object being measured meet the design requirements to ensure accurate data acquisition; the detection components need to be debugged and calibrated after installation to ensure normal operation.

[0071] Example 2:

[0072] The anchor clamp performance testing method disclosed in this invention is implemented using the anchor clamp performance and hydraulic cylinder pressure holding testing system of Embodiment 1 described above. Before testing, preliminary preparations must be completed: first, assemble all components of the entire device according to design requirements, ensuring secure connections and proper installation; then, based on the synchronous elevator design parameters, select multiple anchor clamps of suitable size and identical specifications as test objects for installation, ensuring good contact between the anchor clamps and the steel strands; subsequently, debug the entire system's operating status, calibrate the measurement accuracy of each sensor, and check for leaks in the hydraulic system; finally, record initial data, specifically including hydraulic pressure sensor readings, load values, dial gauge slippage, etc., as a benchmark for subsequent testing and comparison. The reaction frame, synchronous elevator, and anchor clamps are simulated in an actual construction scenario, while an industrial camera and electron microscope are separately installed in the laboratory for further analysis of the anchor clamps after testing, ensuring the test results are accurate, reliable, and meet practical engineering needs.

[0073] Specifically, the above-mentioned testing method includes static testing, dynamic testing, and dynamic load testing. Data collected at each stage is used to comprehensively evaluate the performance of the anchor clamp and the pressure-holding performance of the lifting cylinder. The specific steps are as follows:

[0074] I. Static Testing:

[0075] Static testing is used to test the static clamping performance of the anchor clips and the pressure holding performance of the lifting cylinder after self-locking. The specific steps of this static testing are as follows:

[0076] The two first synchronous lifters are controlled to load in stages according to a set load step (e.g., 10t). After each stage is loaded to the preset load value, the pressure is held for a first set time (the first set time is 5 minutes), and then the unloading operation is performed. Throughout the loading, pressure holding, and unloading process, load data is collected by hydraulic pressure sensors, relative slippage data between the anchor clamp and the steel strand is collected by dial gauges, and noise data is collected by noise sensors. All data are transmitted to the data acquisition system for storage in real time. At the same time, the load stability during the pressure holding process of the lifter cylinder is detected by hydraulic pressure sensors.

[0077] After each unloading stage is completed, images of the steel strand indentation and anchor tooth profile are captured using an industrial camera. The anchor clamps are then disassembled and their contact surfaces with the steel strands are cleaned with acetone. Microscopic damage to the contact surfaces is then examined using an electron microscope. After each stage of testing, a new anchor clamp of the same specification is replaced and reassembled before the next stage of load testing is performed. The above steps are repeated until the preset peak load (e.g., 100t) is completed for each stage of testing. The static slippage alarm threshold is 0.3mm. If the slippage exceeds the threshold, the loading for that stage is immediately stopped.

[0078] During loading, the hydraulic system pressure is gradually adjusted, and the readings of the oil pressure sensor, the slippage data from the dial indicator, and the noise data from the noise sensor are recorded in real time. This data will be used to analyze the performance changes of the anchor clamp under different loads, continuously monitor the slippage change curve, observe whether the slippage is stable, record the maximum value and trend of the slippage, and continuously monitor the pressure holding performance after the lifter cylinder self-locks. This process will help evaluate the stability and reliability of the anchor clamp under high loads. After each unloading stage, images of the steel strand indentation are captured using an industrial camera, and the changes in the indentation are recorded. These images will be used for subsequent analysis of the deformation of the steel strand under different loads. During the static unloading process, the hydraulic components of the synchronous lifter are controlled to gradually reduce the hydraulic system pressure, allowing the synchronous lifter to unload according to the set load steps. The residual slippage and the depth of the steel strand rebound indentation are recorded to analyze the clamping performance of the anchor clamp after unloading. This data will be used to evaluate the recovery and residual deformation of the anchor clamp after unloading.

[0079] Dynamic detection:

[0080] Dynamic testing is used to test the reliability and durability of anchor clip disengagement and the reliability of anchor mechanism movement, while also testing the cyclic pressure holding performance of the lifting cylinder.

[0081] The specific steps of this dynamic detection include:

[0082] Step 1: Control one of the first synchronous lifting devices to lock the first group of steel strands. After the other first synchronous lifting device completes the anchoring action, load it with the rated working load and the overload load exceeding the rated load by 10% in turn. After loading to the corresponding load value, hold the pressure for a preset time. Then control the cylinder of the first synchronous lifting device to unload and control its anchor mechanism to perform the anchor release action, so that the anchor clamp is separated from the anchor plate and the steel strands.

[0083] Step 2: Repeat the anchoring, loading, pressure holding, unloading, and anchor release process from Step 1. After each set number of executions (e.g., 50 times), adjust the stroke of the first synchronous lifting cylinder to ensure that the engagement points of the anchor clamp and the steel strand are not concentrated in the same area.

[0084] Throughout the testing process, the hydraulic pressure sensor records load data in real time and monitors the pressure holding stability of the lifting cylinder. The noise sensor collects noise data. After each unloading, an industrial camera captures images of the steel strand indentation and the anchor tooth profile. After disassembling the anchor clamps and cleaning the contact surfaces with acetone, an electron microscope is used to inspect for microscopic damage. Displacement images of the anchor clamp group are acquired using an industrial endoscope arranged in a ring array. These images are transmitted to the analysis system via a data acquisition system. A deep learning model extracts the pixel coordinates of the anchor clamp group's center point in the images. By transforming the pixel coordinate system with the world coordinate system, the actual displacement difference between the anchor clamp groups is calculated. Based on these displacement differences, the number of anchor clamps with abnormal displacement is identified, and the corresponding load values ​​and test cycles are recorded.

[0085] If an abnormal noise is generated when the anchor wrench is unloaded and detached during the rated load test, the test for that load level should be terminated immediately and the total number of test rounds recorded. After replacing the anchor wrench with a new one, steps one and two should be repeated with an overload load. If an abnormal noise is detected during the overload load test, the total number of test rounds should be recorded and the dynamic test should be terminated.

[0086] II. Dynamic load testing:

[0087] Dynamic load testing is used to detect the clamping performance of anchor wedges under dynamic load conditions, and at the same time to detect the pressure holding stability of the lifting cylinder under dynamic load interference.

[0088] The specific steps for dynamic load detection are as follows:

[0089] The second synchronous lifter is controlled to load to the rated load value, and after holding the load for a set time (e.g., 10 minutes), the unloading operation is performed. During the holding load period, the excitation cylinder is controlled to apply a periodic dynamic load of a set size (e.g., 100t) and a set frequency (e.g., 1.5Hz) to the anchor clamp, with the duration consistent with the holding load duration. This simulates the external dynamic load on the anchor clamp under actual working conditions. The dynamic load curve is recorded in real time by the hydraulic pressure sensor throughout the process, and the load stability during the holding process of the second synchronous lifter cylinder is detected. The dynamic slippage fluctuation between the anchor clamp and the steel strand is detected by a dial indicator. The displacement alarm threshold is 0.5mm. If the dynamic displacement exceeds the dynamic displacement alarm threshold or the load fluctuation exceeds the set range during the pressure holding process of the lifting cylinder, the pressure relief and shutdown will be triggered immediately to ensure the safety of the testing process. This function will ensure that if any abnormal situation occurs during the testing process, timely measures can be taken to avoid equipment damage and personnel injury. After unloading or shutdown, images of the steel strand indentation and anchor tooth surface are taken with an industrial camera and compared with the initial image to determine the wear status. The wear location and degree are recorded. After the anchor clip is disassembled and the contact surface is cleaned with acetone, the microscopic damage of the contact surface is detected using the electron microscope.

[0090] The electron microscopy inspection process after each working condition test is standardized: the contact surface between the anchor and the steel strand is cleaned with acetone to remove residual dirt; the stress concentration area at the root of the wrench tooth (3 locations) and the deepest point of the steel strand indentation (2 locations) are selected as the observation areas; at 1000x magnification, the changes in the metallographic structure of the contact surface (such as martensitic phase transformation and microcrack formation) are analyzed, the surface wear level is evaluated according to ISO 25178 standard, and the microcrack size (identification threshold ≥5μm) is recorded. Through microscopic inspection, the wear condition of the wrench and potential failure risk can be more accurately assessed.

[0091] Specifically, by integrating the three sets of test data, and based on the test data from the static test, dynamic test, and dynamic load test, the performance of the anchor clamp and the pressure holding performance of the lifting cylinder are evaluated in the following manner:

[0092] Static inspection stage: Based on the images captured by the industrial camera and the microscopic damage detected by the electron microscope, the maximum load that is indistinguishable to the naked eye but poses a safety risk in the microscopic state is defined, and this load is taken as the theoretical value of the critical point for safe use of the anchor clamp; combined with the load data, pressure holding stability, slippage data and noise data during the inspection process, the clamping performance of the anchor clamp and the pressure holding performance of the lifting cylinder under static working conditions are comprehensively judged.

[0093] Dynamic testing phase: Based on images captured by industrial cameras, microscopic damage detected by electron microscopes, and the number of test cycles in which anchoring noises occur, the reliability and durability of the anchor wedges under dynamic working conditions are comprehensively judged; based on displacement data collected by industrial endoscopes, the motion reliability of the anchor mechanism is evaluated; and combined with load fluctuation data during the pressure holding process of the lifting cylinder, the cyclic pressure holding performance of the lifting cylinder is evaluated.

[0094] Dynamic load testing phase: Based on images captured by industrial cameras, microscopic damage detected by electron microscopy, dynamic load data, and slippage data, the clamping performance and anti-interference stability of the anchor clamp under dynamic load conditions are evaluated; combined with the pressure holding fluctuation data of the lifting cylinder, the pressure holding stability of the lifting cylinder under dynamic load interference is evaluated.

[0095] After a comprehensive evaluation of the anchor wrench's performance, targeted optimization suggestions can be proposed based on the evaluation results. For example, if the anchor wrench's performance is found to be insufficient under a certain working condition, improvements to the wrench design, replacement with more suitable materials, or adjustment of the hydraulic system parameters can be considered. Based on the optimization suggestions, improvements can be made to the anchor wrench or the testing device. After improvement, the above testing process is repeated to verify the effectiveness of the improvements until the anchor wrench's performance under static, dynamic, and dynamic load conditions meets the actual engineering requirements (stable performance and conforms to design requirements), providing a reliable basis for subsequent use and maintenance, and forming a final evaluation report.

[0096] Those skilled in the art should understand that variations can be implemented by combining existing technology with the above embodiments. Such variations do not affect the essence of the present invention and will not be elaborated upon here.

[0097] The preferred embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and the devices and structures not described in detail should be understood as being implemented in a conventional manner in the art. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the present invention. This does not affect the essential content of the present invention. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the present invention's technical solutions still fall within the protection scope of the present invention.

Claims

1. A system for testing the performance of anchor clamps and the pressure holding function of a lifting cylinder, characterized in that, It includes a static and dynamic performance testing device, a dynamic load performance testing device, a pressure accessory system, and testing components, wherein the pressure accessory system provides hydraulic power to the static and dynamic performance testing device and the dynamic load performance testing device; The static and dynamic performance testing device includes a static and dynamic performance testing reaction frame fixed in the test area, two first synchronous lifters and a first set of steel strands. The two first synchronous lifters are respectively located on both sides of the static and dynamic performance testing reaction frame. A through channel is opened inside the static and dynamic performance testing reaction frame. A steel strand guide device is installed in the through channel. The first set of steel strands passes through the steel strand guide device, and both ends of the first set of steel strands are equipped with anchor clips. The anchor clips on both sides are respectively connected to the first synchronous lifter on the corresponding side through their bearing anchor plates. The dynamic load performance testing device includes a dynamic load performance testing reaction frame, a second synchronous lifter, an excitation cylinder, and a second set of steel strands. The dynamic load performance testing reaction frame consists of a first reaction frame, a second reaction frame, and a third reaction frame located between the two. Each reaction frame is equipped with a steel strand guide device. The excitation cylinder is located between the first and third reaction frames, and its telescopic end is fixedly connected to the third reaction frame. The third reaction frame and the second reaction frame are fixedly connected by a connecting bracket. The second synchronous lifter is located on the outer side of the second reaction frame away from the third reaction frame. One end of the second set of steel strands is fixed to the test area, and the other end passes through the steel strand guide devices of each reaction frame in sequence and is then assembled with an anchor clamp. The anchor clamp is connected to the second synchronous lifter through its bearing anchor plate. The detection components include a hydraulic pressure sensor, a dial gauge, a noise sensor, an industrial camera, an industrial endoscope, an electron microscope, and a data acquisition system. The data acquisition system is communicatively connected to the hydraulic pressure sensor, dial gauge, noise sensor, industrial endoscope, industrial camera, and electron microscope. Furthermore, each reaction frame, synchronous lifter, and anchor clamp is arranged according to the actual construction scenario.

2. The anchor clamp performance and lifting cylinder pressure holding test system as described in claim 1, characterized in that, The hydraulic pressure sensor is installed in the pressure accessory system and is used to detect the load applied by the first synchronous lift cylinder, the second synchronous lift cylinder and the excitation cylinder. The dial gauges are respectively installed on the exposed end side of the anchor clamp to detect the relative slippage between the anchor clamp and the steel strand; The noise sensors are respectively installed on the static and dynamic performance test reaction frame and the dynamic load performance test reaction frame, and are used to collect noise data during the loading, unloading and cyclic operation stages of the test process; The industrial endoscope ring array is arranged around the anchor mechanism of the first synchronous lifter, and the displacement consistency of the anchor clamp group is detected through the gap between the end cap of the anchor mechanism and the cylinder. The industrial camera and electron microscope are arranged in the laboratory. The industrial camera is used to capture images of steel strand indentations and anchor tooth profiles, and the electron microscope is used to detect microscopic damage at the contact surface between the anchor clip and the steel strand.

3. The anchor clamp performance and lifting cylinder pressure holding test system as described in claim 1, characterized in that, The static and dynamic performance test reaction frames, including the first reaction frame, the second reaction frame, and the third reaction frame, are all rigid frame structures.

4. The anchor clamp performance and lifting cylinder pressure holding test system as described in claim 1, characterized in that, Limiting rings are fixedly provided at both the upper and lower ends of the third reaction frame. A limiting rod is fixedly provided on the first reaction frame at the position corresponding to the limiting ring. The end of the limiting rod away from the first reaction frame passes through the limiting ring to form a limiting and guiding structure.

5. The anchor clamp performance and lifting cylinder pressure holding detection system as described in claim 1, characterized in that, The pressure accessory system includes four independent hydraulic components, which are respectively connected to the second synchronous lift cylinder, the excitation cylinder and the two first synchronous lift cylinders to provide independent hydraulic power to each cylinder.

6. A method for testing the performance of anchor clamps and the pressure holding function of the lifting cylinder, characterized in that, The anchor clamp performance and lifting cylinder pressure holding test system described in any one of claims 1 to 5 are used. The method includes three test stages: static test, dynamic test and dynamic load test. The test data are collected through each stage to comprehensively evaluate the performance of the anchor clamp and the pressure holding performance of the lifting cylinder. The static test is used to test the clamping performance of the anchor clip and the pressure holding performance after the lifting cylinder self-locks. By controlling the first synchronous lifting device to load, hold pressure and unload step by step, the test data is collected synchronously and micro and macro tests are completed. After each test, the anchor clip is replaced until the preset peak load test is completed. The dynamic detection is used to detect the reliability and durability of the anchor clips' disengagement and the reliability of the anchor mechanism's movement, while also detecting the cyclic pressure holding performance of the lifting cylinder. By controlling one first synchronous lifting device to lock, and another first synchronous lifting device to alternately tighten and loosen the anchor and cyclically load, the detection data is collected in real time. Combined with endoscopic displacement detection and microscopic and macroscopic detection, the test ends when an abnormality occurs. The dynamic load detection is used to detect the clamping performance of the anchor wedge under dynamic load conditions, and at the same time to detect the pressure holding stability of the lifting cylinder under dynamic load interference. By controlling the second synchronous lifter to load and maintain pressure, the periodic dynamic load is applied synchronously using the excitation cylinder. Real-time data collection and detection are performed to monitor the slippage and pressure status. If any abnormality occurs, the machine is immediately unloaded or stopped. After replacing the anchor clamp, subsequent testing is completed.

7. The method for testing the performance of anchor clamps and the pressure holding function of the lifting cylinder as described in claim 6, characterized in that, The specific steps of the static detection are as follows: The first synchronous lifter is controlled to load the load step by step according to the set load step. After each load reaches the preset load value, the pressure is maintained for a first set time, and then the unloading operation is performed. Throughout the loading, pressure holding, and unloading process, load data is collected using the hydraulic pressure sensor, relative slippage data between the anchor clamp and the steel strand is collected using the dial indicator, and noise data is collected using the noise sensor. All data is transmitted to the data acquisition system for storage. Simultaneously, the load stability during the pressure holding process of the lifting cylinder is detected using the hydraulic pressure sensor. After each unloading stage, images of the steel strand indentation and anchor tooth profile are captured using an industrial camera. The anchor clamp is then disassembled, and its contact surface with the steel strand is cleaned with acetone. Microscopic inspection is then performed using an electron microscope. After that, a new anchor clamp is replaced, and the next stage of loading and testing continues until the preset peak load is completed.

8. The method for testing the performance of anchor clamps and the pressure holding of the lifting cylinder as described in claim 7, characterized in that, The dynamic detection steps specifically include: Step 1: Control one of the first synchronous lifting devices to lock the first group of steel strands. After the other first synchronous lifting device completes the anchoring action, load it with the rated working load and the overload load exceeding the rated load by 10% in turn. After loading to the corresponding load value, hold the pressure for a preset time. Then control the cylinder of the first synchronous lifting device to unload and control its anchor mechanism to perform the anchor release action, so that the anchor clamp is separated from the anchor plate and the steel strands. Step 2: Repeat the anchoring, loading, pressure holding, unloading, and anchor release process from Step 1. After each set number of executions, adjust the stroke of the first synchronous lifting cylinder to ensure that the engagement points of the anchor clamp and the steel strand are not concentrated in the same area. Throughout the testing process, the hydraulic pressure sensor records load data in real time and monitors the pressure holding stability of the lifting cylinder. The noise sensor collects noise data. After each unloading, an industrial camera captures images of the steel strand indentation and the anchor tooth profile. After disassembling the anchor clamps and cleaning the contact surfaces with acetone, an electron microscope is used to inspect for microscopic damage. Displacement images of the anchor clamp group are acquired using an industrial endoscope arranged in a ring array. These images are transmitted to the analysis system via a data acquisition system. A deep learning model extracts the pixel coordinates of the anchor clamp group's center point in the images. By transforming the pixel coordinate system with the world coordinate system, the actual displacement difference between the anchor clamp groups is calculated. Based on these displacement differences, the number of anchor clamps with abnormal displacement is identified, and the corresponding load values ​​and test cycles are recorded. If an abnormal noise is generated when the anchor wedge is unloaded and detached during the rated load test, the rated load test shall be terminated immediately and the total number of test cycles shall be recorded. After replacing the anchor wedge with a new one, steps one and two shall be repeated with an overload load. If an abnormal noise is detected during the overload load test, the total number of test cycles shall be recorded and the dynamic test shall be terminated.

9. The method for testing the performance of anchor clamps and the pressure holding of the lifting cylinder as described in claim 7, characterized in that, The specific steps for dynamic load detection are as follows: The second synchronous lifter is controlled to load to the rated load value, and after holding the load for a set time, the unloading operation is performed; during the holding load period, the excitation cylinder is controlled to apply a periodic dynamic load of a set size and a set frequency to the anchor clamp, and the duration is consistent with the holding load duration; The dynamic load curve is recorded in real time by the oil pressure sensor throughout the process, and the load stability during the pressure holding process of the second synchronous lifter cylinder is detected. The dynamic slippage fluctuation between the anchor clamp and the steel strand is detected by a dial indicator, with a dynamic slippage alarm threshold of 0.5 mm. If the dynamic slippage exceeds the dynamic slippage alarm threshold or the load fluctuation exceeds the set range during the pressure holding process of the lifting cylinder, pressure relief and shutdown are triggered immediately. After unloading or shutdown, images of the steel strand indentation and anchor tooth profile are captured by the industrial camera. After the anchor clamp is disassembled and the contact surface is cleaned with acetone, the microscopic damage of the contact surface is detected by the electron microscope.

10. The method for testing the performance of anchor clamps and the pressure holding function of the lifting cylinder as described in claim 6, characterized in that, Based on the test data from the static, dynamic, and dynamic load tests, the performance of the anchor clamp and the pressure-holding performance of the lifting cylinder are evaluated as follows: Static inspection stage: Based on the images captured by the industrial camera and the microscopic damage detected by the electron microscope, the maximum load that is indistinguishable to the naked eye but poses a safety risk in the microscopic state is defined, and this load is taken as the theoretical value of the critical point for safe use of the anchor clamp; combined with the load data, pressure holding stability, slippage data and noise data during the inspection process, the clamping performance of the anchor clamp and the pressure holding performance of the lifting cylinder under static working conditions are comprehensively judged. Dynamic detection phase: Based on the images captured by the industrial camera, the microscopic damage detected by the electron microscope, and the number of test rounds in which the anchoring noise occurred, the reliability and durability of the anchor wedge under dynamic working conditions are comprehensively judged; based on the displacement data collected by the industrial endoscope, the motion reliability of the anchor mechanism is evaluated. The cyclic pressure holding performance of the lifter cylinder is evaluated by combining load fluctuation data during the pressure holding process of the lifter cylinder. Dynamic load testing stage: Based on the images captured by the industrial camera, the microscopic damage detected by the electron microscope, the dynamic load data and slippage data, the clamping performance and anti-interference stability of the anchor clip under dynamic load conditions are evaluated. By combining the pressure holding fluctuation data of the lifter cylinder, the pressure holding stability of the lifter cylinder under dynamic load disturbance is evaluated.

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