Self-powering monitoring device of motorized winch and whole life cycle monitoring method thereof

Abstract

The application discloses a kind of self-power monitoring device of motor winch and its whole life cycle monitoring method, it is related to power construction technical field.Conventional motor winch cannot carry out state monitoring due to no external power supply.The present application includes mechanical magnetic power generation module, resistance strain gauge, power conversion and charging unit, annular control circuit board and micro battery;Mechanical magnetic power generation module and resistance strain gauge are arranged on the low-speed shaft that motor winch gearbox extends, annular control circuit board integrates rotation speed acquisition, wireless communication and satellite positioning function, processes data and uploads cloud through wireless communication module, and cloud statistics winch working state, load condition, position distribution and utilization, provide data support for equipment procurement decision, use, use and maintenance, for equipment procurement decision, use, use and maintenance provide data support.The uninterrupted monitoring of energy self-sufficiency is realized, mainly used for the working state of conventional motor winch is remotely monitored, realizes whole life cycle monitoring management.

Description

Technical Field

[0001] This invention relates to the field of power construction technology, and in particular to a self-powered monitoring device for a motorized winch and its full life-cycle monitoring method. Background Technology

[0002] In power tower erection and line stringing construction, motorized winches, especially gasoline-powered winches, are key construction tools, widely used in tower erection, wire hanging, accessory installation, and cable laying. These machines have advantages such as reasonable structure, small size, light weight, high power, flexible operation, and convenient transportation, and are used in large numbers in power construction.

[0003] However, in the actual management of motorized construction equipment such as winches, especially in-service equipment, it is difficult to accurately count the actual utilization rate of winches due to the inability to monitor and collect their actual usage status and data in real time. It is also difficult to effectively control the reasonable quantity of equipment used by the construction project department, and even more difficult to provide effective data support for the annual procurement plan. Summary of the Invention

[0004] The technical problem to be solved and the technical task proposed by this invention is to improve and refine existing technical solutions, and to provide a self-powered monitoring device for motorized winches and its full life cycle monitoring method, so as to realize the digital monitoring transformation of existing traditional motorized winches and achieve the goal of energy self-sufficiency full life cycle monitoring and intelligent management. To this end, this invention adopts the following technical solution.

[0005] A self-powered monitoring device for a motorized winch includes a mechatronic power generation module, a resistance strain gauge, a power conversion and charging unit, a ring control circuit board, and a micro battery. The mechatronic power generation module and the resistance strain gauge are mounted on a low-speed shaft extending from the gearbox of the motorized winch. The power conversion and charging unit and the ring control circuit board are mounted on the end face of the gearbox housing. The micro battery is mounted on the ring control circuit board. The mechatronic power generation module is electrically connected to the power conversion and charging unit, which is electrically connected to the ring control circuit board. The resistance strain gauge is also electrically connected to the ring control circuit board. The ring control circuit board is further electrically connected to a speed acquisition unit, a wireless communication module, and a satellite positioning module. The ring control circuit board is wirelessly connected to a cloud server via the wireless communication module. The speed acquisition unit is configured to extract a speed signal from the output signal of the mechatronic power generation module.

[0006] Power is drawn directly from the low-speed shaft of the winch extending from the gearbox via a mechanical magnetic power generation module. During operation, this module powers the monitoring device and charges the micro-battery. During shutdown, the micro-battery powers the monitoring device, completely solving the power supply problem for the monitoring device in field construction environments. This enables uninterrupted monitoring throughout the entire lifecycle. By integrating multiple sensing units such as torque, speed, and position, the device can easily collect and generate monitoring data for relevant equipment and transmit it to a cloud server for analysis and processing via a wireless communication module. This provides data support for the full lifecycle management of the equipment. The monitoring device can also easily perform digital monitoring upgrades on existing traditional motorized winches, giving them digital monitoring capabilities.

[0007] As a preferred technical approach, the wireless communication module and satellite positioning module are mounted on a ring-shaped control circuit board. Integrating the communication and positioning modules onto the circuit board simplifies on-site installation and modification, eliminating the need for additional installation space and wiring for the communication and positioning modules. The structure is simple, on-board structures are widely used, and the technology is mature.

[0008] As a preferred technical approach, the mechanical magnetic power generation module includes a power generation gear and a magnetic power generation material. The module is powered by a low-speed shaft via a gear transmission structure. Specifically, a transmission gear is mounted on the low-speed shaft, meshing with the power generation gear. When the winch operates, the low-speed shaft drives the transmission gear to rotate, which in turn drives the power generation gear to rotate synchronously. The power generation gear then causes the magnetic power generation material to move relative to it, generating electrical energy. Power transmission via gear meshing offers good structural reliability and stability, high transmission efficiency, and strong energy conversion capability, ensuring sufficient power generation to support the entire monitoring system.

[0009] As a preferred technical approach, the transmission gear is connected to low-speed shafts of different diameters via an adjustable inner diameter coupling. This adjustable inner diameter coupling allows the same monitoring device to be quickly adapted to different models and shaft diameters of in-service motorized winches, significantly improving the product's market coverage and cost-effectiveness in retrofitting.

[0010] A method for monitoring the entire lifecycle of a self-powered monitoring device for a motorized winch includes the following steps:

[0011] 1) The mechanical magnetic power generation module generates a periodic alternating electromotive force as the low-speed shaft rotates. After being rectified and regulated by the power conversion and charging unit, it powers the ring control circuit board, wireless communication module and satellite positioning module, and charges the micro battery. When the motor winch stops, the micro battery powers the ring control circuit board and key sensing components to maintain a low-power monitoring state. 2) The resistance strain gauge collects the torque signal of the low-speed shaft and transmits it to the ring control circuit board. The speed acquisition unit collects the speed signal of the low-speed shaft and transmits it to the ring control circuit board. The ring control circuit board performs analog-to-digital conversion and data analysis processing, converting the torque signal into the grinding cylinder shaft torque and the low-speed shaft speed signal into the grinding cylinder operating speed. It also synchronously accumulates the grinding cylinder working time based on the low-speed shaft speed signal. 3) The satellite positioning module collects the position information of the winch and transmits it to the ring control circuit board; 4) The ring control circuit board packages the mill cylinder rotation speed, mill cylinder shaft torque, mill cylinder working time, position information and battery power data, and sends them to the cloud server through the wireless communication module; 5) The cloud server performs real-time analysis and processing of the received data, and statistically analyzes the working status, load, location distribution and utilization rate of the winch, providing data support for equipment procurement decisions, requisition, use and maintenance, and realizing full life cycle monitoring and management.

[0012] This method constructs a full-process monitoring system encompassing "power generation-acquisition-transmission-analysis," covering core parameters such as torque, speed, operating time, and location. It can easily collect, upload, and analyze information such as the mill cylinder's operating speed, cylinder shaft torque, mill cylinder operating time, location information, and battery power data. This data forms decision-making data such as equipment utilization and load distribution, providing data support for equipment procurement decisions, requisition, use, and maintenance. It enables full lifecycle monitoring and management, reducing blind spots in operation and maintenance.

[0013] As a preferred technical approach: In step 2), the speed acquisition unit converts the alternating electromotive force signal into a standard pulse signal as the low-speed shaft speed signal through filtering and shaping circuits. The ring control circuit board converts the standard pulse signal into the speed of the winch drum based on the number of magnet poles of the mechanical magnetic power generation module. The working time of the winch drum is accumulated according to the duration of the standard pulse signal. Timing stops when the speed is zero and the standard pulse signal disappears. Speed ​​acquisition is achieved through the alternating electromotive force signal of the mechanical magnetic power generation module, eliminating the need for a separate speed sensor, simplifying the hardware structure and reducing costs.

[0014] As a preferred technical approach: In step 2), the main control MCU on the ring control circuit board uses a periodic sleep and dynamic sleep time adjustment wake-up mechanism to monitor the motorized winch. Specifically, the dynamic sleep time adjustment means automatically adjusting the sleep time parameter to match the previous sleep time based on the previously collected motorized winch speed status. Compared to fixed-period monitoring, this "dynamic sleep" mechanism allows for adaptive adjustment of the monitoring frequency according to the equipment's operating conditions, avoiding unnecessary energy consumption.

[0015] As a preferred technical approach: When monitoring the motorized winch, the main control MCU is awakened according to a preset or dynamically adjusted sleep time to perform status monitoring. When the mill cylinder speed is detected to be greater than zero, indicating that it is in working condition, the main control MCU shortens the sleep time to increase the monitoring frequency and collects the low-speed shaft speed signal and torque signal. The low-speed shaft torque signal is converted into the mill cylinder shaft torque, and the low-speed shaft speed signal is converted into the winch cylinder operating speed. At the same time, the winch cylinder working time is accumulated. When the mill cylinder speed is detected to be zero, indicating that it is in shutdown or warehouse storage condition, the main control MCU extends the sleep time to reduce the monitoring frequency. The wireless communication module is normally in a power-off state. The main control MCU controls the wireless communication module to be powered on once a day at a set time. After the wireless communication module sends the positioning information to the main control MCU, the main control MCU uploads the daily winch cylinder working time, winch cylinder operating speed, mill cylinder shaft torque, positioning information (i.e., winch equipment map coordinates), and battery power data package to the cloud server. After the upload is completed, the main control MCU immediately cuts off the power supply to the wireless communication module and enters a sleep state. In working conditions, the sleep time is shortened to increase the monitoring frequency and ensure the real-time performance of high-load data; in shutdown conditions, the sleep time is extended to significantly reduce the energy consumption of the micro battery and extend the battery life. The wireless communication module is powered on at a set time every day to avoid power waste caused by continuous power supply, while ensuring timely uploading of daily data, balancing low power consumption and data integrity.

[0016] As a preferred technical approach: In step 5), regarding the statistical analysis of load conditions, the cloud server divides the winch load when the winch cylinder's operating speed is greater than zero into three load ranges—high, medium, and low—based on a preset torque threshold. It records the corresponding cylinder shaft torque value and winch cylinder operating time for each range, thereby statistically analyzing the actual load and usage of the equipment. By quantifying the equipment load distribution, compared to general statistics, it can more accurately reflect the actual usage intensity of the equipment, correlate the operating time of each load range, provide data support for component fatigue life assessment, and reduce the risk of sudden failures.

[0017] As a preferred technical approach: when calculating the actual load on the equipment, if the torque of the grinding cylinder shaft exceeds the preset overload threshold and the duration reaches a set value, the cloud server immediately triggers an overload warning and records the equipment location, operating time, and load data at the time of the warning. By using dual warning conditions of torque exceeding the limit and duration, false warnings caused by instantaneous impacts are avoided, improving the reliability of the warning. Simultaneously recording information such as location and operating time facilitates tracing overload scenarios and provides a basis for optimizing equipment operation procedures and defining responsibilities.

[0018] Beneficial effects: 1. The monitoring device is installed on the gearbox housing of a traditional motorized winch. It draws power directly from the low-speed shaft of the winch that extends out of the gearbox through a mechanical magnetic power generation module. During operation, it directly powers the monitoring device and charges the micro battery. During shutdown, it powers the monitoring device through the micro battery, which completely solves the power supply problem of the monitoring device in the field construction environment and realizes uninterrupted monitoring throughout the entire life cycle of the monitoring device.

[0019] 2. The monitoring device integrates multiple sensing units such as torque, speed, and position, covering core parameters such as torque, speed, working time, and position. It can easily collect and upload information such as the mill cylinder's operating speed, mill cylinder shaft torque, mill cylinder working time, position information, and battery power data.

[0020] 3. The cloud server analyzes and processes the collected data to generate decision-making data such as equipment utilization and load distribution, providing accurate data support for equipment procurement decisions, requisition scheduling, usage standards, and maintenance, realizing full lifecycle monitoring and management, and reducing blind operation and maintenance.

[0021] 4. The main control MCU's dynamic sleep / wake-up mechanism and the daily timed power-on data transmission mechanism of the wireless communication module increase the monitoring frequency during operation, ensure data real-time performance, extend the sleep time during shutdown to reduce energy consumption, avoid power waste caused by continuous power supply, and ensure timely daily data upload, significantly improving the micro battery's endurance.

[0022] 5. By using dual warning conditions of torque exceeding limits and duration, overload warnings can be effectively achieved, avoiding false warnings caused by instantaneous impacts and improving the reliability of warnings; by synchronously recording information such as location and working duration, it is easy to trace overload scenarios and provide a basis for optimizing equipment operation specifications and defining responsibilities.

[0023] 6. The transmission gear of the mechanical magnetic power generation module adopts the "one type, multiple fit" design of adjustable coupling assembly or multi-specification bushing, which can be adapted to low-speed shafts of different diameters. There is no need to customize special parts for different models, reducing the adaptation cost and the difficulty of modifying traditional motorized winches. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of a traditional motorized winch.

[0025] Figure 2 This is a schematic diagram of the monitoring device of the present invention.

[0026] Figure 3 This is a schematic diagram of the monitoring device module layout according to the low-speed axial end view of the present invention.

[0027] Figure 4 This is a schematic diagram of low-speed shaft power extraction according to the present invention.

[0028] Figure 5 This is a schematic diagram of the wake-up mechanism of the main control MCU of the present invention, which dynamically adjusts the sleep time.

[0029] Figure 6 This is a schematic diagram of the power-on process of the main control MCU controlling the wireless communication module of the present invention.

[0030] Figure 7 This is a schematic diagram of the cloud server device analysis and early warning mechanism of the present invention.

[0031] In the diagram: 1. Gasoline engine; 2. Gearbox; 3. Grinding cylinder; 4. Winch base; 5. Low-speed shaft; 6. Mechanical magnetic power generation module; 7. Resistance strain gauge; 8. Power conversion and charging unit; 9. Ring control circuit board; 10. Micro battery; 11. Wireless communication module; 12. Satellite positioning module; 13. Speed ​​acquisition unit; 14. Cloud server; 601. Generating gear; 602. Transmission gear; 603. Magnetic power generation material; 801. Three-phase rectifier circuit; 802. Voltage regulator circuit and charging chip. Detailed Implementation

[0032] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings.

[0033] Example 1 like Figure 1 The image shows a traditional motorized winch, comprising a gasoline engine 1, a clutch and gearbox 2, a mill cylinder 3, and a winch base 4. The gasoline engine 1 is the power source, providing power output and a low-voltage electrical signal upon startup. The gearbox 2 is the power transmission unit, achieving different speeds through multi-stage reduction and clutch switching. The output shaft is connected to the mill cylinder 3, and the clutch and gearbox 2 reduce speed and increase torque, ultimately driving a steel cable through the mill cylinder 3 to achieve traction of several tons during construction. Traditional motorized winches are simply power conversions between a combustion engine and mechanical transmission, lacking digital and monitoring systems. With the rapid development of the power construction industry, the number of power construction equipment, including traditional motorized winches, has increased significantly every year. However, these winches are characterized by their simplistic and inefficient design. Some equipment operates under continuous overload conditions, and others suffer from unreasonable configurations and low utilization rates due to a lack of monitoring and control measures.

[0034] Because motorized winches are individual units, numerous and varying in weight from hundreds to hundreds of kilograms, their power source is a gasoline engine with no external power supply interface. Furthermore, motorized winches are engineering equipment, returned to the equipment warehouse for maintenance after completing a construction project. To achieve full lifecycle monitoring of the motorized winches, a power supply method combining a data acquisition module with its own battery and a self-charging system is required. In this embodiment, the self-charging modification relies on the rotation of the low-speed shaft 5 extending from the motorized winch's gearbox 2 to generate electricity. Even if the equipment is not used for extended periods, the monitoring device can still be powered by its built-in micro-battery 10, with an average power consumption of only mA.

[0035] like Figure 2 , 3 As shown, a self-powered monitoring device for a motorized winch includes a mechanical magnetic power generation module 6, a resistance strain gauge 7, a power conversion and charging unit 8, a ring control circuit board 9, and a micro battery 10. The mechanical magnetic power generation module 6 is mounted on a low-speed shaft 5 extending from the gearbox 2 of the motorized winch to directly draw power.

[0036] Resistance strain gauges 7 are mounted on the low-speed shaft 5 extending from the gearbox 2 of the motorized winch. The power conversion and charging unit 8 and the ring control circuit board 9 are fixed to the end face of the gearbox 2 housing. Two micro-batteries 10 are symmetrically arranged on the ring control circuit board 9. The mechanical magnetic power generation module 6 is electrically connected to the power conversion and charging unit 8, and the power conversion and charging unit 8 is electrically connected to the ring control circuit board 9. Figure 4 As shown, the power conversion and charging unit 8 includes a three-phase rectifier circuit 801, a voltage regulator circuit, and a charging chip 802. During operation, it converts the three-phase AC power generated by the generator module into stable DC power, directly supplying power to the monitoring device and charging the micro-battery 10. During shutdown, the micro-battery 10 supplies power to the monitoring device, completely solving the power supply problem for the monitoring device in field construction environments and achieving uninterrupted monitoring throughout its entire lifecycle. The resistance strain gauge 7 is electrically connected to the ring control circuit board 9. The resistance strain gauge 7 is attached to the stress position of the low-speed shaft 5 of the grinding cylinder 3. The strain gauge's leads are connected to the ring control circuit board 9 via tinned copper wire or shielded cable. The bridge circuit interface on the control circuit board 9 is connected to ensure that the solder joints are firm and free of cold solder joints. In this embodiment, the bridge circuit interface adopts a half-bridge or full-bridge Wheatstone bridge. The ring control circuit board 9 is also electrically connected to the speed acquisition unit 13, the wireless communication module 11, and the satellite positioning module 12. The ring control circuit board 9 is wirelessly connected to the cloud server 14 through the wireless communication module 11. By integrating multiple sensing units such as torque, speed, and position, it can easily collect and generate monitoring data of relevant equipment and transmit it to the cloud server 14 for analysis and processing through the wireless communication module 11, providing data support for the full life cycle management of the equipment.

[0037] To achieve stable and reliable power generation capacity, such as Figure 4 As shown, the mechanical magnetic power generation module 6 includes a power generation gear 601 and a magnetic power generation material 603. The mechanical magnetic power generation module 6 is powered by a low-speed shaft 5 through a gear transmission structure. Specifically, a transmission gear 602 is installed on the low-speed shaft 5, which meshes with the power generation gear 601. When the winch is working, the low-speed shaft 5 drives the transmission gear 602 to rotate, which in turn drives the power generation gear 601 to rotate synchronously. The power generation gear 601 drives the magnetic power generation material 603 to move relative to each other, generating electrical energy. Power transmission through gear meshing has good structural reliability and stability, high transmission efficiency, and strong energy conversion capability, ensuring that the power generation is sufficient to support the entire monitoring system.

[0038] A method for monitoring the entire lifecycle of a self-powered monitoring device for a motorized winch, comprising the following steps: S1: Self-powered: The mechanical magnetic power generation module 6 generates a periodic alternating electromotive force as the low-speed shaft 5 rotates. After being rectified and regulated by the power conversion and charging unit 8, it powers the ring control circuit board 9, the wireless communication module 11, and the satellite positioning module 12, and charges the micro battery 10. When the motorized winch stops, the micro battery 10 powers the ring control circuit board 9 and key sensing components to maintain a low-power monitoring state. S2: Data Acquisition and Processing: The resistance strain gauge 7 acquires the torque signal of the low-speed shaft 5 and transmits it to the ring control circuit board 9; the speed acquisition unit 13 converts the alternating electromotive force signal into a standard pulse signal as the speed signal of the low-speed shaft 5 through filtering and shaping circuits, and transmits it to the ring control circuit board 9, eliminating the need for a separate speed sensor; the ring control circuit board 9 performs analog-to-digital conversion and data analysis, converting the torque signal of the low-speed shaft 5 into the grinding cylinder shaft torque, and converting the standard pulse signal into the grinding cylinder operating speed based on the number of magnet poles of the mechanical magnetic power generation module 6, and accumulating the grinding cylinder working time according to the duration of the standard pulse signal. When the speed is zero, the standard pulse signal disappears, and the timing stops; S3: Location information acquisition: Satellite positioning module 12 acquires the position information of the winch and transmits it to the ring control circuit board 9; S4: Data upload: The ring control circuit board 9 packages the data of the mill cylinder rotation speed, mill cylinder shaft torque, mill cylinder working time, position information and battery power, and uploads them to the cloud server 14 through the wireless communication module 11. S5: Cloud Analysis and Early Warning: The cloud server 14 performs real-time analysis and processing of the received data, and statistically analyzes the working status, graded load range, location distribution and utilization rate of the winch, providing data support for component fatigue life assessment, and providing data support for equipment procurement decisions, requisition, use and maintenance, realizing full life cycle monitoring and management; in addition, when overload operation is detected, an overload warning will be issued to reduce the risk of sudden failure.

[0039] In step S2, the ring control circuit board 9 is equipped with a main control MCU. The main control MCU uses a periodic sleep and dynamic sleep time adjustment wake-up mechanism to collect and monitor data from the motorized winch. The dynamic sleep time adjustment is based on the previously collected motorized winch speed status, which automatically adjusts the sleep time parameters to match the next sleep time. The main control MCU performs sleep and wake-up according to the automatically adjusted sleep time parameters. Specifically: when the speed of the grinding cylinder 3 is detected to be greater than zero, i.e., it is in working condition, the main control MCU shortens the sleep time to increase the monitoring frequency, and collects the speed signal and torque signal of the low-speed shaft 5. The torque signal of the low-speed shaft 5 is converted into the grinding cylinder shaft torque, and the speed signal of the low-speed shaft 5 is converted into the winch grinding cylinder operating speed. At the same time, the working time of the winch grinding cylinder is accumulated. When the speed of the grinding cylinder 3 is detected to be zero, i.e., it is in a stopped or warehouse storage condition, the main control MCU extends the sleep time to reduce the monitoring frequency. The shortening of the sleep time and the increase of the monitoring frequency in working condition ensure the real-time performance of high-load data. Employing a dynamic sleep mechanism, compared to fixed-period monitoring, the monitoring frequency can be adaptively adjusted according to the equipment's operating conditions, avoiding unnecessary energy consumption, significantly reducing the power consumption of the micro-battery 10, and extending its battery life. The following describes the wake-up mechanism adopted by the main control MCU, which includes periodic sleep and dynamic adjustment of sleep time: Figure 5 As shown, this mechanism is implemented according to the following process: S201: The main control MCU enters periodic sleep standby according to the preset sleep interval time; S202: Check whether the monitoring interval meets the preset time. If yes, proceed to the next step; otherwise, return to step S201. S203: Determine whether the grinding cylinder 3 is rotating. If yes, proceed to the next step; otherwise, proceed to step S207. S204: Collect the rotation speed of the mill cylinder 3; S205: Perform local calculations, accumulation, and updates on the collected real-time data to form the statistical data for the day, and then proceed to the next step; S206: Reduce the next sleep time and return to step S201; S207: Increase the next sleep time and return to step S201.

[0040] In step S4, the wireless communication module 11 is normally in a power-off state. The main control MCU controls the wireless communication module 11 to power on once daily at a set time, and then uploads the various data packets to the cloud server 14 via the wireless communication module 11. Figure 6 As shown, the specific implementation process is as follows: S401: The main control MCU is in standby sleep mode, and the wireless communication module 11 is in a power-off state; S402: When the main control MCU determines that the current time is consistent with the preset data upload time for the day, that is, exactly 24 hours have passed, it will proceed to the next step. If the time has not been reached, it will return to step S401 and continue to sleep. S403: The main control MCU is woken up and powered on. The wireless communication module 11 sends the location information to the main control MCU. S404: The main control MCU will package the daily working time of the winch, the speed of the winch, the torque of the winch shaft, the positioning information (i.e., the map coordinates of the winch equipment), and the battery power data and upload them to the cloud server 14 through the wireless communication module 11.

[0041] S405: After the upload is completed, the main control MCU immediately cuts off the power supply to the wireless communication module 11, and then the main control MCU enters sleep mode.

[0042] The wireless communication module 11 is powered on at a set time every day to avoid power waste caused by continuous power supply, while ensuring timely data upload every day, balancing low power consumption and data integrity.

[0043] like Figure 7 As shown, in step S5, the data received by the cloud server 14 is first stored in the equipment information database as the basic equipment information for analysis and statistics. Then, the cloud server 14 performs equipment working time statistics and equipment utilization rate statistics on the basic equipment information. When calculating equipment working time, the total daily working hours are considered, which is roughly equivalent to the winch's working time. If this time exceeds 30 minutes, and excluding situations where the equipment is being repaired, tested, or debugged in the warehouse, and the location is not in the company warehouse, it is considered as one working day. The number of working days / 365 days is used as the rule for calculating the winch's utilization rate. By statistically analyzing the utilization rate of all winches in the company, effective data support can be provided for the annual procurement decision of motorized winches. The daily usage of all winches in each project can be statistically analyzed, allowing for control over whether the number of motorized winches requisitioned by the construction project department is reasonable, providing a basis for the subsequent configuration of each project. The equipment working time and equipment utilization rate data are synchronized to the equipment monitoring and management module of the cloud server 14.

[0044] The equipment monitoring and management module statistically analyzes the received actual equipment load information. During the statistical analysis, the equipment load is categorized into intervals. The cloud server 14 divides the winch load when the mill cylinder's operating speed is greater than zero into three load intervals: high, medium, and low, based on a preset torque threshold range. It records the corresponding mill cylinder shaft torque value and the winch cylinder's operating time for each interval. By quantifying the equipment load distribution, compared to general statistics, it more accurately reflects the actual usage intensity of the equipment. Corresponding to the working time of each load interval provides a reference for equipment maintenance time, avoiding construction accidents caused by prolonged equipment fatigue. In this embodiment, when the preset torque threshold range is defined, low load is <30% of rated torque, medium load is 30%-70% of rated torque, and high load is >70% of rated torque.

[0045] The equipment monitoring and management module analyzes high-load usage based on the statistical equipment load information for different load ranges and compares it with the pre-entered equipment specifications and rated load information. If the equipment is used under high load, it will send information to the equipment monitoring and management module to shorten the maintenance cycle for reference in the equipment maintenance cycle assessment.

[0046] When the grinding cylinder shaft torque exceeds the preset overload threshold and the duration reaches the set value in the equipment load information, in this embodiment, when the load is >100% of the rated torque and the duration is greater than the set value of 5 seconds, the cloud server 14 immediately triggers an overload warning and records the equipment location, working duration, and load data at the time of the warning. This overload warning mechanism avoids false warnings caused by instantaneous impacts and improves the reliability of the warning by using dual warning conditions of torque exceeding the limit and duration. By synchronously recording information such as location and working duration, it is easy to trace overload scenarios and provide a basis for optimizing equipment operation specifications and defining responsibilities.

[0047] In addition, the equipment monitoring module determines whether the equipment is within the authorized project scenario and route range based on the equipment's location information every day. If the location is far from the authorized area, an abnormal location will be displayed, and the person in charge of the equipment should be promptly notified and the equipment should be tracked down.

[0048] This device and method construct a full-process monitoring system encompassing "power generation-acquisition-transmission-analysis," covering core parameters such as torque, speed, operating time, and location. It can easily collect, upload, and process information such as the mill cylinder's operating speed, cylinder shaft torque, mill cylinder operating time, location information, and battery power data to the cloud and backend. This generates decision-making data such as equipment utilization and load distribution, and provides an overload early warning mechanism. It provides data support for equipment procurement decisions, requisition, use, and maintenance, achieving full lifecycle monitoring and management and reducing blind operation and maintenance.

[0049] This invention is not only applicable to the digital monitoring and transformation of traditional motorized winches, but also applicable to other devices with the same transmission mechanism as traditional motorized winches. It can generate electricity from the low-speed transmission shaft of the extended equipment, providing energy support for the entire life cycle and monitoring. By using sensors and monitoring strategies, it can collect and analyze the core elements of the equipment, statistically analyze the equipment's working status, graded load range, location distribution and utilization rate, provide data support for component fatigue life assessment, and provide data support for equipment procurement decisions, requisition, use and maintenance, thus realizing full life cycle monitoring and management.

[0050] In this embodiment, the satellite positioning module 12 adopts a GPS positioning module; the wireless communication module 11 adopts a 4G communication module; the micro battery 10 adopts a lithium-ion battery; the mechanical magnetic power generation module 6 is based on the principle of permanent magnet generator, and the power generation depends on the rotation speed and the number of magnetic poles; the resistance strain gauge 7 is used to measure torque, and based on the strain effect, it needs to be calibrated; the main control MCU is a microcontroller unit responsible for data processing and control, and the model can be STM32 or ESP32, supporting low power mode.

[0051] Example 2 The wireless communication module 11 and the satellite positioning module 12 are mounted on the ring control circuit board 9. Integrating the communication and positioning modules on the circuit board reduces the number of connection and fixing points compared to mounting them on the housing end face of the motor winch gearbox 2. On-site installation and modification are simpler, eliminating the need for additional installation space and wiring for the communication and positioning modules. The structure is simple, and on-board structures are widely used and the technology is mature.

[0052] Example 3 The transmission gear 602 is connected to low-speed shafts 5 of different diameters via an adjustable inner diameter coupling. The adjustable coupling assembly or bushing design allows the same monitoring device to be quickly adapted to in-service motorized winches of different models and shaft diameters, greatly improving the product's market coverage and retrofit cost-effectiveness. In this embodiment, the adjustable inner diameter coupling can be a coupling with an adjustable inner diameter; alternatively, annular bushings of different inner diameters can be selected, and the bushings can be replaced with different inner diameters and then fixed by fasteners; or a tapered elastic sleeve can be used, which can be fitted onto low-speed shafts 5 of different diameters, and then the inner circumference of the transmission gear 602 and the outer circumference of the tapered elastic sleeve are threaded together.

[0053] The above are specific embodiments of the present invention, which demonstrate the outstanding substantive features and significant progress of the present invention. Based on the actual needs of use, equivalent modifications in shape, structure, etc., can be made to it according to the teachings of the present invention, and all such modifications are within the scope of protection of this solution.

Claims

1. A self-powered monitoring device for a motorized winch, characterized in that: The device includes a mechanical magnetic power generation module, a resistance strain gauge, a power conversion and charging unit, a ring control circuit board, and a micro battery. The mechanical magnetic power generation module and the resistance strain gauge are mounted on a low-speed shaft extending from the gearbox of a motorized winch. The power conversion and charging unit and the ring control circuit board are mounted on the end face of the gearbox housing. The micro battery is mounted on the ring control circuit board. The mechanical magnetic power generation module is electrically connected to the power conversion and charging unit, which is electrically connected to the ring control circuit board. The resistance strain gauge is also electrically connected to the ring control circuit board. The ring control circuit board is also electrically connected to a speed acquisition unit, a wireless communication module, and a satellite positioning module. The ring control circuit board is wirelessly connected to a cloud server via the wireless communication module. The speed acquisition unit is configured to extract a speed signal from the output signal of the mechanical magnetic power generation module.

2. The self-powered monitoring device for a motorized winch according to claim 1, characterized in that: The wireless communication module and satellite positioning module are mounted on a ring control circuit board.

3. The self-powered monitoring device for a motorized winch according to claim 1, characterized in that: The mechanical magnetic power generation module includes a power generation gear and a magnetic power generation material. The mechanical magnetic power generation module is powered by a low-speed shaft through a gear transmission structure. Specifically, a transmission gear is set on the low-speed shaft, which meshes with the power generation gear. When the winch is working, the low-speed shaft drives the transmission gear to rotate, which in turn drives the power generation gear to rotate synchronously. The power generation gear drives the magnetic power generation material to move relative to each other and generate electrical energy.

4. The self-powered monitoring device for a motorized winch according to claim 3, characterized in that: The transmission gear is connected to low-speed shafts of different diameters via an adjustable inner diameter coupling.

5. A method for monitoring the entire lifecycle of a self-powered monitoring device for a motorized winch as described in claim 1, characterized in that... Includes the following steps: 1) The mechanical magnetic power generation module generates a periodic alternating electromotive force as the low-speed shaft rotates. After being rectified and regulated by the power conversion and charging unit, it powers the ring control circuit board, wireless communication module and satellite positioning module, and charges the micro battery. When the motor winch stops, the micro battery powers the ring control circuit board and key sensing components to maintain a low-power monitoring state. 2) The resistance strain gauge collects the torque signal of the low-speed shaft and transmits it to the ring control circuit board. The speed acquisition unit collects the speed signal of the low-speed shaft and transmits it to the ring control circuit board. The ring control circuit board performs analog-to-digital conversion and data analysis processing, converting the torque signal into the grinding cylinder shaft torque and the low-speed shaft speed signal into the grinding cylinder operating speed. It also synchronously accumulates the grinding cylinder working time based on the low-speed shaft speed signal. 3) The satellite positioning module collects the position information of the winch and transmits it to the ring control circuit board; 4) The ring control circuit board packages the mill cylinder rotation speed, mill cylinder shaft torque, mill cylinder working time, position information and battery power data, and sends them to the cloud server through the wireless communication module; 5) The cloud server performs real-time analysis and processing of the received data, and statistically analyzes the working status, load, location distribution and utilization rate of the winch, providing data support for equipment procurement decisions, requisition, use and maintenance, and realizing full life cycle monitoring and management.

6. The method for full life-cycle monitoring of a self-powered monitoring device for a motorized winch according to claim 5, characterized in that: In step 2), the speed acquisition unit converts the alternating electromotive force signal into a standard pulse signal as a low-speed shaft speed signal through filtering and shaping circuits. The ring control circuit board converts the standard pulse signal into the speed of the winch drum based on the number of magnet poles of the mechanical magnetic power generation module. The working time of the auger drum is accumulated based on the duration of the standard pulse signal. The timing stops when the rotation speed is zero and the standard pulse signal disappears.

7. The method for full life-cycle monitoring of a self-powered monitoring device for a motorized winch according to claim 5, characterized in that: In step 2), the main control MCU on the ring control circuit board uses a periodic sleep and dynamic sleep time adjustment wake-up mechanism to monitor the motorized winch. The dynamic sleep time adjustment specifically means that the next sleep time parameter is automatically adjusted to match the motorized winch speed status collected in the previous step.

8. The method for full life-cycle monitoring of a self-powered monitoring device for a motorized winch according to claim 7, characterized in that: When monitoring the motorized winch, the main control MCU is awakened according to a preset or dynamically adjusted sleep time to perform status monitoring. When the mill cylinder speed is detected to be greater than zero, indicating that it is in working condition, the main control MCU shortens the sleep time to increase the monitoring frequency and collects the low-speed shaft speed signal and torque signal. The low-speed shaft torque signal is converted into the mill cylinder shaft torque, and the low-speed shaft speed signal is converted into the winch cylinder operating speed. At the same time, the winch cylinder working time is accumulated. When the mill cylinder speed is detected to be zero, indicating that it is in shutdown or warehouse storage condition, the main control MCU extends the sleep time to reduce the monitoring frequency. The wireless communication module is normally in a power-off state. The main control MCU controls the wireless communication module to be powered on once a day at a set time. The wireless communication module obtains the positioning information and sends it to the main control MCU. The main control MCU uploads the daily winch cylinder working time, winch cylinder operating speed, mill cylinder shaft torque, positioning information, and battery power data to the cloud server. After the upload is completed, the main control MCU immediately cuts off the power supply to the wireless communication module and enters sleep state.

9. The method for full life-cycle monitoring of a self-powered monitoring device for a motorized winch according to claim 5, characterized in that: In step 5), regarding the analysis and statistics of the load, the cloud server divides the winch load when the winch drum's operating speed is greater than zero into three load ranges: high, medium, and low, based on the torque threshold preset according to the equipment's rated parameters. It records the corresponding drum shaft torque value and winch drum working time for each range, and thus compiles statistics on the actual load and usage of the equipment.

10. The method for monitoring the entire life cycle of a self-powered monitoring device for a motorized winch according to claim 9, characterized in that: When the grinding cylinder shaft torque exceeds the preset overload safety threshold and the duration reaches the set value within the high load range, the cloud server immediately triggers an overload warning and records the equipment location, working duration, and load data at the time of the warning.

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