A continuous monitoring system and method for slack of steel wire rope for carbon car

Abstract

The embodiment of the application discloses a kind of for carbon car's steel wire rope slackness continuous monitoring system and method, it is related to the steel wire rope safety monitoring technical field of multifunctional car in carbon industry baking workshop.Scheme includes: fixed seat (6), swing arm (7), counterweight roller assembly (10), inclination detection unit and signal processing unit;Counterweight roller assembly (10) is attached to steel wire rope (1), swing arm (7) is reset by dead weight, inclination gauge is integrated in swing arm (7), and the attitude change caused by loose rope and broken rope is converted into continuous angle signal;Signal processing unit is built-in filter algorithm to prevent shaking, and two-stage software adjustable threshold value is provided, corresponding output early warning or emergency stop signal.Can improve the reliability of monitoring system under harsh working conditions and reduce structural complexity.

Description

Technical Field

[0001] This invention relates to the field of wire rope safety monitoring technology for multi-functional overhead cranes in carbon industry roasting workshops, and particularly to a continuous monitoring system and method for wire rope slack of carbon overhead cranes. Background Technology

[0002] As a core load-bearing and transmission component in mechanical equipment, the working condition of wire rope directly affects the operational safety and service life of the equipment. Wire ropes are subjected to dynamic loads over long periods, making them prone to failures such as gradual slack, creep elongation, and sudden breakage. Therefore, reliable monitoring devices are needed to identify risks promptly.

[0003] Existing wire rope slack detection technologies mainly rely on two types of solutions: one is the "mechanical structure + switch sensor" solution, which uses mechanical structures such as spring reset and hydraulic damping, combined with contact sensors such as microswitches and limit switches to achieve detection. For example, some patents use springs to pull the connecting frame to trigger electrical switches, or use compressed springs to push movable rods to trigger limit switches, such as existing technologies CN213598901U and CN220928883U; the other is the "counterweight traction + position detection" solution, which uses the gravity of the counterweight to drive the guide wheel assembly, and uses limit switches to detect the position of the counterweight to determine the slack rope status, such as CN213087593U.

[0004] However, existing technologies have significant drawbacks: the detection dimensions are discrete, and they can only output "normal" or "abnormal" switching signals. They cannot capture the continuous change process of the wire rope from tension to relaxation, making it difficult to identify early hidden dangers such as creep elongation and gradual relaxation, and they cannot achieve preventive maintenance. Furthermore, in order to avoid false alarms due to normal elastic vibration during wire rope operation, complex mechanical limit or damping structures need to be set up.

[0005] Another improved approach is to detect the wire rope tension by monitoring the tilt angle. However, such solutions often require indirect detection using intermediate components. For example, in CN 121321674 A, the wire rope tension is determined by monitoring the lifting lugs. This approach still suffers from structural complexity. For instance, if the lifting lugs are integrated with the bucket, their rotation is synchronized with the bucket's rotation, allowing only indirect inference of the wire rope's condition. If the bucket is jammed, the wire rope's condition cannot be accurately determined. However, it is generally usable in normal temperature environments or non-extreme working conditions. However, in harsh working conditions such as carbon roasting workshops, the complex mechanical structures present reliability issues. Components such as springs, hydraulic dampers, and lifting lugs are prone to fatigue fractures, oil leaks, and aging. Contact switches are susceptible to wear and oxidation failure, significantly reducing the lifespan of the device. Furthermore, due to the need for tension springs, torsion springs, and hydraulic dampers, these solutions also suffer from cumbersome threshold adjustments. Adjusting the detection threshold requires physical adjustments to mechanical clearances and spring preload, resulting in high operational complexity and an inability to flexibly adapt to different working conditions. Indirect detection solutions are also prone to amplifying monitoring errors in harsh environments.

[0006] Therefore, how to improve the safety monitoring scheme for wire rope slackness and breakage under harsh working conditions, enhance the reliability of the monitoring system, and reduce structural complexity has become a research topic. (Invention Content)

[0007] The embodiments of the present invention provide a continuous monitoring system and method for the slack of steel wire ropes for carbon cranes, which can directly monitor the steel wire rope itself, improve the reliability of the monitoring system under harsh working conditions and reduce structural complexity.

[0008] To achieve the above objectives, the embodiments of the present invention adopt the following technical solutions:

[0009] In a first aspect, embodiments of the present invention provide a continuous monitoring system for the slack of a steel wire rope for a carbon crane, comprising: a mechanical coupling part and a measuring module; the mechanical coupling part is attached to the steel wire rope (1); the mechanical coupling part is reset by its own weight through a swing arm structure;

[0010] The measurement module includes: an inclination detection unit, a signal processing unit, and an inclinometer, the inclinometer being mounted on the swing arm structure; the inclination detection unit is used to collect attitude angle data from the inclinometer and then transmit it to the signal processing unit; the signal processing unit is used to obtain and output continuous monitoring results based on the slack of the wire rope (1), the continuous monitoring results being used to indicate the defective state of the wire rope (1), the types of defective states including at least slack rope and broken rope states, wherein the continuous monitoring results obtained by the signal processing unit include at least: continuous monitoring results of the inclinometer, graded control signals, and zero-point offset prompts, etc.

[0011] Specifically, the mechanical coupling part includes: a fixed seat (6), a swing arm (7) and a counterweight roller assembly (10); one end of the swing arm (7) is connected to the fixed seat (6) by a rotating positioning nut (5) and resets by gravity; the other end of the counterweight roller assembly (10) is rotatably connected to the swing arm (7) so that the counterweight roller assembly (10) fits against the wire rope (1) and drives the swing arm (7) to rotate with the change of tension of the wire rope (1).

[0012] The rotating shaft (2) is installed between the corresponding rotating positioning nuts (5) of the two swing arms (7); the length of the swing arms (7) can be adjusted according to the installation space, and one end of the swing arm (7) is rotatably connected to the bearing seat (4) of the fixed seat (6) through the rotating shaft (2). The reset power source of the swing arm (7) is only its own weight. One end of the swing arm (7) is rotatably connected to the bearing seat (4) of the fixed seat (6) through the rotating shaft (2). The other end of the swing arm (7) is equipped with a bearing, and the counterweight roller assembly (10) is installed on the bearing and forms a rotatable connection.

[0013] Furthermore, a nylon sleeve is fitted around the outer periphery of the counterweight roller assembly (10). The nylon sleeve rolls in contact with the wire rope (1) to reduce frictional wear on the wire rope (1). The counterweight roller assembly (10) is fitted with a detachable nylon sleeve. The surface of the nylon sleeve is treated with anti-slip and wear-resistant coating to reduce frictional wear on the wire rope (1). The sleeve can be replaced individually after wear, reducing maintenance costs.

[0014] The inclinometer is installed on the swing arm (7) and converts the attitude changes caused by the slack and breakage of the wire rope (1) into angle signals.

[0015] Optionally, both the tilt detection unit and the signal processing unit are encapsulated within an integrated housing (9); the tilt detection unit and the signal processing unit are integrated and encapsulated within the same waterproof and dustproof integrated housing (9); the integrated housing (9) is provided with an output interface (8) for communicating with an external controller and transmitting monitoring signals. The integrated housing (9) has an output interface (8). The signal processing unit has an output interface (8), which includes an RS485 interface or an IO interface, for communicating with an external controller and transmitting monitoring signals.

[0016] Optionally, the mounting base (6) has mounting holes and is installed on the equipment fixed support structure adjacent to the wire rope drum or wire rope guide wheel, so that the counterweight roller assembly (10) is located above or to the side of the wire rope (1). The mounting base (6) is used to fix and connect to the equipment frame. For example, the mounting base (6) has mounting holes and is installed on the equipment fixed support structure adjacent to the wire rope (1) drum or guide wheel by bolts or welding, ensuring that the installation is stable and does not interfere with the lifting and lowering movement of the wire rope (1). The installation position can be flexibly adjusted according to the actual working conditions so that the counterweight roller assembly (10) fits against the upper or side of the wire rope (1), ensuring that the tension change of the wire rope (1) can be accurately transmitted to the swing arm (7) and improving the detection sensitivity.

[0017] Secondly, embodiments of the present invention provide a method for continuous monitoring of wire rope slack for carbon cranes, applied to the aforementioned system, the method comprising:

[0018] The tilt angle detection unit collects the attitude angle data of the swing arm (7) relative to the vertical line of gravity, and converts the attitude angle data into an electrical signal and outputs it to the signal processing unit.

[0019] The signal processing unit runs a data processing model through a built-in microprocessor, processes the received electrical signals through the data processing model, and then outputs a continuous monitoring signal of the slack of the wire rope (1). The data processing model includes a filtering algorithm anti-shake part, which corresponds to two adjustable thresholds for outputting warning and emergency stop signals. The filtering algorithm anti-shake part can use a moving average filtering algorithm to filter out the high-frequency elastic shaking signal generated during the operation of the wire rope (1) and only respond to angle changes whose duration exceeds a preset threshold. The signal processing unit has a built-in microprocessor (MCU) and integrates a power supply module, a signal acquisition module, a filtering processing module, a threshold judgment module, and a communication module. The data processing algorithm includes a moving average filtering algorithm, which calculates the weighted average of the acquired angle data by setting a sliding window, filters out the high-frequency elastic shaking signal, and only responds to angle changes whose duration exceeds the set threshold, effectively avoiding false alarms. At least two adjustable thresholds are configured: the first threshold corresponds to slight slack of the wire rope (1), which outputs a warning signal after triggering; the second threshold corresponds to severe slack or breakage of the wire rope (1), which outputs an emergency stop signal after triggering. The two thresholds can be modified by sending external commands to the host computer or PLC without disassembling the device. The signal processing unit transmits the slack measurement value of the wire rope (1) and the corresponding graded control signals (early warning / emergency stop / normal) to the external controller (such as PLC, industrial computer, equipment main control system) through the output interface (8).

[0020] Optionally, the tilt detection unit uses a MEMS tilt sensor, which can capture minute angle changes of the swing arm (7) in real time. The sensor's sensitive axis is parallel to the rotation axis of the swing arm (7) and is fixed to the swing arm (7) near the counterweight roller assembly (10). The protection level is not lower than IP65, making it suitable for dusty and humid environments in industrial settings. The tilt detection unit is connected to the signal processing unit via wires, converting the collected attitude angle analog signal into a digital electrical signal for output.

[0021] Furthermore, the two adjustable thresholds include: a first threshold corresponding to the slightly slack state of the wire rope (1), and an early warning signal is output when the wire rope (1) reaches the slightly slack state as determined by the first threshold and the continuous monitoring signal of the slack of the wire rope (1); and a second threshold corresponding to the severely slack or broken state of the wire rope (1), and an emergency stop signal is output when the wire rope (1) reaches the severely slack or broken state as determined by the second threshold and the continuous monitoring signal of the slack of the wire rope (1). It should be noted that the severely slack and broken states of the wire rope (1) both refer to the wire rope having no supporting force, which can be uniformly understood as the state that causes the wire rope to lose its supporting force, and therefore correspond to the same threshold (i.e., the second threshold).

[0022] The embodiments of the present invention provide a continuous monitoring scheme for the slack of steel wire ropes for carbon cranes, solving the technical defects of existing equipment that rely on switching sensors, cannot quantify the degree of slack, have weak anti-interference, are cumbersome in threshold adjustment, and are prone to mechanical failure. It includes a fixed base (6), a swing arm (7), a counterweight roller assembly (10), an inclination detection unit, and a signal processing unit; the counterweight roller assembly (10) is attached to the steel wire rope (1) so that it can directly receive the force on the steel wire rope and monitor the steel wire rope; the swing arm (7) is self-realigned, and the inclination meter is integrated into the swing arm (7) to convert the attitude changes caused by slack and broken ropes into continuous angle signals; the signal processing unit has a built-in filtering algorithm for anti-shake, and two levels of software adjustable thresholds are set to output warning or emergency stop signals accordingly. It realizes continuous monitoring of slack from qualitative to quantitative, and the gravity swing arm is directly pressed on the steel wire rope and reset by gravity, which can directly reflect the state of the steel wire rope. The structure is simple and the detection results are more direct and accurate. Suitable for continuous monitoring of wire rope slack in extreme working conditions workshops, it can improve the reliability of the monitoring system under harsh conditions and reduce structural complexity. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1This is a schematic diagram of the measurement module provided in an embodiment of the present invention. Figure 1 The steel wire rope (1) in the middle is in a taut state;

[0025] Figure 2 This is a schematic diagram of the measurement module provided in an embodiment of the present invention. Figure 2 The steel wire rope (1) in the middle is not taut, and the swing arm (7) returns to the predetermined position by gravity in the direction of gravity;

[0026] Figure 3 This is a schematic diagram of the structure provided for an embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the installation state in a practical application of the embodiment of the present invention.

[0028] The components in the attached diagram are labeled as follows: Wire rope-1, Rotating shaft-2, Fixing bolt group-3, Bearing seat-4, Rotating positioning nut-5, Fixing seat-6, Swing arm-7, Output interface-8, Integrated housing-9, Counterweight roller assembly-10. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Embodiments of the present invention will be described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention. Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” “the,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in the specification of the present invention means the presence of the stated features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. It should be understood that when we say an element is “connected” or “coupled” to another element, it can be directly connected or coupled to the other element, or there may be intermediate elements. Furthermore, “connected” or “coupled” as used herein can include wireless connections or couplings. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the meaning consistent with their meaning in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein.

[0030] This invention is applicable to various mechanical equipment such as cranes, winches, elevators and mine hoists, which use steel wire rope (1) as the core load-bearing component. It is used to realize continuous quantitative monitoring of the slack state of steel wire rope (1) and early warning of rope breakage, so as to ensure the safe operation of the equipment.

[0031] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment takes the monitoring scenario of the suction pipe wire rope of a multi-functional overhead crane in a carbon roasting workshop as an example. As shown in Figure 1, the monitoring device includes a fixed base (6), a swing arm (7), a counterweight roller assembly (10), an inclination detection unit, and a signal processing unit. Optionally, the inclination detection unit and the signal processing unit can be integrated and packaged in the same integrated housing (9). The fixed base (6) is installed on the fixed support structure adjacent to the wire rope (1) drum by bolts or welding, providing a stable installation reference for the entire device. The bearing housing (4) is installed on the fixed seat (6) by the fixing bolt group (3). One end of the swing arm (7) is rotatably connected to the bearing housing (4) by the rotating shaft (2) and the rotating positioning nut (5). The cooperation between the rotating shaft (2) and the bearing housing (4) ensures that the swing arm (7) rotates flexibly without jamming. The other end of the swing arm (7) is rotatably connected to the counterweight roller assembly (10) by the bearing. The outer circumference of the counterweight roller assembly (10) is fitted with a nylon sleeve. The nylon sleeve is in contact with the upper surface of the wire rope (1). When the wire rope (1) moves, it can drive the counterweight roller assembly (10) to rotate synchronously, reducing the frictional loss of the wire rope (1).

[0032] The integrated housing (9) is fixedly installed on the swing arm (7) near the counterweight roller assembly (10). Figure 3 As shown, the sensitive axis of the tilt detection unit inside is parallel to the rotation axis of the swing arm (7), which can accurately collect continuous data of the attitude angle of the swing arm (7) relative to the vertical line of gravity; the signal processing unit has a built-in microprocessor and data processing algorithm, which is electrically connected to the tilt detection unit to receive and process the angle electrical signal. The integrated housing (9) is provided with an output interface (8), including an RS485 interface and an IO interface, which are connected to an external controller (such as a PLC) through wires to realize signal transmission.

[0033] After the device is installed and assembled, a "tension-relaxation" range calibration must be performed to ensure monitoring accuracy. The specific operation is as follows:

[0034] Zero point calibration: The wire rope (1) is in normal tension. At this time, the tension of the wire rope (1) provides stable support for the counterweight roller assembly (10), and the swing arm (7) maintains the initial attitude angle. The tilt angle detection unit collects the attitude angle data and transmits it to the signal processing unit. The external controller sends the "zero point calibration" command, and the signal processing unit calibrates the angle as the reference zero point, corresponding to a slack of 10%.

[0035] Range calibration: Manually adjust the tension of the wire rope (1) to gradually relax it to complete relaxation. At this time, the swing arm (7) rotates to the limit attitude angle under its own gravity. The tilt angle detection unit collects the limit attitude angle data and transmits it to the signal processing unit. The external controller sends the "range calibration" command, and the signal processing unit calibrates the angle as the end point of the range, corresponding to a relaxation degree of 90%.

[0036] Model generation: The signal processing unit automatically calculates the angle-relaxation conversion model parameters (relaxation = (k × angle + b) × 100%, where k and b are calibration coefficients) based on the calibrated zero point and range endpoint data. After calibration, the device enters normal monitoring state.

[0037] Threshold setting: After calibration, the external controller sends a command to the signal processing unit to configure two levels of software adjustable thresholds. The threshold setting is determined according to the equipment operating conditions: First threshold (slight slack threshold): corresponding to the state of slight slack in the wire rope (1), set to slack of 40%, and outputs a warning signal after triggering; Second threshold (severe slack / rope breakage threshold): corresponding to the state of severe slack or sudden breakage in the wire rope (1), set to slack of 80%, and outputs an emergency stop signal after triggering.

[0038] The working principle of this embodiment:

[0039] Initial calibration stage: After the device is installed, the wire rope (1) is under normal tension. Its tension applies a supporting force to the swing arm (7) through the counterweight roller assembly (10), so that the swing arm (7) maintains a stable initial attitude angle. The tilt angle detection unit collects this initial angle value and transmits it to the signal processing unit as the reference zero point. By manually adjusting the slack of the wire rope (1), the swing arm (7) is made to be at the attitude angle corresponding to the complete slack rope. The tilt angle detection unit collects this angle value and transmits it to the signal processing unit to complete the tension-slack range calibration.

[0040] Normal operation monitoring phase: During the lifting and lowering of the wire rope (1), the tilt detection unit collects the attitude angle data of the swing arm (7) in real time and transmits it to the signal processing unit through the wire. The signal processing unit starts the moving average filtering algorithm (existing algorithm tools can be used) to perform noise reduction processing on the original angle data, filter out the high-frequency interference signal generated by the normal elastic vibration of the wire rope (1) (the noise reduction process can also be done in the existing way), and obtain a smooth angle change curve.

[0041] Based on the preset angle-slack conversion model: slack = (k * angle + b) × 100%, where k and b are two calibration coefficients. For example: after on-site installation, under tensioned conditions, the tilt sensor returns an angle of 30 degrees, and under fully relaxed conditions, the tilt sensor angle is 40 degrees. In order to leave a calculation margin, the slack corresponding to the fully tensioned state is 10%, and the slack corresponding to the relaxed state is 90%. Substituting these values ​​into the angle-slack conversion model, we can obtain k = 0.07 and b = -2.0. The filtered angle data is converted into a quantified value of the slack of the wire rope (1) (unit: %), and uploaded to an external controller (such as a PLC or industrial computer) through the output interface (8), while simultaneously outputting the current status signal (normal / warning / emergency stop).

[0042] Slack Rope Warning Stage: When the wire rope (1) becomes slightly slack, its supporting force on the counterweight roller assembly (10) decreases, the swing arm (7) rotates slowly under the action of gravity, the change in attitude angle gradually increases, and the calculated slack of the wire rope (1) gradually increases. When the slack reaches the first threshold and the duration exceeds the preset threshold, the signal processing unit determines it as "slight slack" and outputs a warning signal.

[0043] Emergency stop phase due to rope breakage: When the wire rope (1) is severely slack or broken, its supporting force on the counterweight roller assembly (10) is completely lost, the swing arm (7) rotates rapidly under the action of gravity, and the slack of the wire rope (1) quickly exceeds the second threshold. The signal processing unit immediately determines it as a "serious abnormality" and outputs an emergency stop signal.

[0044] An example illustrating the actual working process of this embodiment:

[0045] In practical applications, such as Figure 4 As shown, the continuous monitoring system for wire rope slack of the carbon crane provided in this embodiment can be selectively installed on the bracket of the winch in the carbon roasting workshop (or it can be installed on other fixed brackets or walls, as long as the wire rope (1) can pass through the counterweight roller assembly (10) under tension and fit against the counterweight roller assembly (10)). The wire rope (1) extends out from the winding reel of the winch. In normal working condition, the counterweight roller assembly (10) fits against the wire rope (1) and drives the swing arm (7) to rotate with the change of tension of the wire rope (1). In bad condition, such as slack rope and broken rope, the fit between the counterweight roller assembly (10) and the wire rope (1) is reduced or even no longer in contact.

[0046] When the wire rope (1) is running normally, its tension supports the counterweight roller assembly (10), the swing arm (7) maintains a stable posture, the tilt detection unit collects angle data in real time and transmits it to the signal processing unit; the signal processing unit filters out the high-frequency elastic jitter interference during the operation of the wire rope (1) through the moving average filtering algorithm, and only responds to angle changes that last for more than a preset threshold, avoiding false alarms, and at the same time, it inputs the conversion model to output the relaxation quantification value, which is synchronously transmitted to the external controller through the output interface (8).

[0047] When the wire rope (1) becomes slightly slack, its supporting force on the counterweight roller assembly (10) decreases, the swing arm (7) rotates slowly, the slack reaches the first threshold and the duration meets the requirements, the signal processing unit outputs a warning signal and a slack quantification value, and the controller starts an audible and visual alarm to prompt the staff to maintain it; when the wire rope (1) is severely slack or broken, the supporting force disappears completely, the swing arm (7) rotates rapidly, the slack reaches the second threshold, and the signal processing unit immediately outputs an emergency stop signal.

[0048] In summary, the wire rope (1) slack continuous monitoring device based on tilt angle sensing provided in this embodiment of the invention ensures monitoring accuracy through complete "tension-slack" range calibration. Combined with flexible two-level software adjustable threshold settings, the gravity reset characteristics of the swing arm (7) and counterweight roller assembly (10), continuous acquisition by the tilt angle detection unit, and intelligent analysis by the signal processing unit, it realizes quantitative monitoring and graded protection of slack. At the same time, it covers rope breakage detection scenarios. The structure is simple and reliable, and the installation and maintenance are convenient, effectively improving the operational safety of lifting equipment.

[0049] Compared with the prior art, the embodiments of the present invention have the following advantages:

[0050] The traditional limit switch is eliminated, removing the easily failed tension spring, torsion spring, and hydraulic damper. It relies entirely on gravity reset, eliminating the risk of spring fatigue fracture and hydraulic leakage at the source. At the same time, the built-in digital filtering algorithm replaces physical damping to filter out the elastic vibration of the wire rope (1), ensuring a fast response to real slack signals and effectively avoiding false actions, significantly improving the stability of the device under harsh working conditions. Using MEMS tilt sensing technology, it can output continuous data of the entire process of the wire rope (1) from tension to slack in real time. It can not only detect sudden rope breakage accidents, but also keenly capture the slight plastic tension of the wire rope (1) due to long-term use. It also supports zero-point calibration and parameterized threshold configuration. During installation, there is no need to repeatedly manually adjust the position of the striker or the spring preload as with traditional devices, which greatly reduces the difficulty of on-site debugging and labor costs. For example, when the wire rope is under normal tension and not in operation, the average stable swing arm posture angle is extracted and compared with the reference zero point. If the angle deviation exceeds 1° and this state lasts for 30 seconds or more, it is determined to be a continuous zero-point deviation, and a zero-point deviation warning signal is immediately output to remind the staff to conduct preventive inspections of the wire rope, avoiding the failure to detect abnormal conditions caused by long-term use in a timely manner. This provides data support for the preventive maintenance of the equipment.

[0051] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on its differences from other embodiments. In particular, the device embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments. The above descriptions are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A continuous monitoring system for the slack of wire ropes in a carbon crane, characterized in that, include: Mechanical coupling components and measurement module; The mechanical coupling part is attached to the steel wire rope (1). The mechanical coupling part is reset by its own weight through the swing arm structure; The measurement module includes: a tilt angle detection unit, a signal processing unit, and a tilt meter, wherein the tilt meter is mounted on the swing arm structure; The tilt angle detection unit is used to collect attitude angle data from the tilt meter and then transmit it to the signal processing unit; The signal processing unit is used to obtain and output continuous monitoring results based on the slack of the wire rope (1). The continuous monitoring results are used to indicate the undesirable state of the wire rope (1). The types of undesirable states include at least slack rope and broken rope states.

2. The system according to claim 1, characterized in that, The mechanical coupling part includes: a fixed base (6), a swing arm (7), and a counterweight roller assembly (10); One end of the swing arm (7) is connected to the fixed seat (6) by rotating the positioning nut (5) and is reset by gravity; the other end of the counterweight roller assembly (10) is rotatably connected to the swing arm (7) so that the counterweight roller assembly (10) fits the wire rope (1) and drives the swing arm (7) to rotate with the change of tension of the wire rope (1).

3. The system according to claim 1, characterized in that, The rotating shaft (2) is installed between the corresponding rotating positioning nuts (5) of the two swing arms (7); A bearing is installed at the other end of the swing arm (7), and a counterweight roller assembly (10) is installed on the bearing to form a rotating connection.

4. The system according to claim 3, characterized in that, The outer periphery of the counterweight roller assembly (10) is fitted with a nylon sleeve, which rolls with the wire rope (1) to reduce frictional wear on the wire rope (1).

5. The system according to claim 1, characterized in that, The inclinometer is installed on the swing arm (7) and converts the attitude changes caused by the slack and breakage of the wire rope (1) into angle signals.

6. The system according to claim 5, characterized in that, Both the tilt detection unit and the signal processing unit are encapsulated within an integrated housing (9); An output interface (8) is provided on the integrated housing (9).

7. The system according to claim 1, characterized in that, The mounting hole is provided on the mounting base (6). The mounting base (6) is installed on the equipment fixed support structure adjacent to the wire rope drum or wire rope guide wheel, so that the counterweight roller assembly (10) is located above or to the side above the wire rope (1).

8. The system according to any one of claims 1-7, characterized in that, The methods implemented through the system include: The tilt angle detection unit collects the attitude angle data of the swing arm (7) relative to the vertical line of gravity, and converts the attitude angle data into an electrical signal and outputs it to the signal processing unit. The signal processing unit runs a data processing model through a built-in microprocessor, processes the received electrical signals through the data processing model, and then outputs a continuous monitoring signal of the slack of the wire rope (1). The data processing model includes a filtering algorithm anti-shake part, which outputs two adjustable thresholds for warning and emergency stop signals.

9. The system according to claim 8, characterized in that, The tilt detection unit uses a MEMS tilt sensor, and the sensitive axis of the MEMS tilt sensor is parallel to the rotation axis of the swing arm (7).

10. The system according to claim 1, characterized in that, The two adjustable threshold levels include: The first threshold corresponds to the slightly slack state of the wire rope (1). When the wire rope (1) is determined to be slightly slack by the first threshold and the continuous monitoring signal of the slack of the wire rope (1), an early warning signal is output. The second threshold corresponds to the severe slack or broken state of the wire rope (1). When the wire rope (1) is determined to be in a severe slack or broken state by the second threshold and the continuous monitoring signal of the slack of the wire rope (1), an emergency stop signal is output.

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