Intelligent physics monitoring system and method for portal main cable traction system

Abstract

The application provides a kind of gantry main cable traction system and method for intellectual ability, monitoring system includes pin shaft force sensor, three-axis tilt sensor, GNSS equipment, plate ring tension sensor, wireless signal collector and control system.The application realizes the real-time correction measurement of flexible traction cable in the state of shaking by the combination of pin shaft force sensor and three-axis tilt sensor, solves the problem of traction cable tension direction change caused by different puller position and difficult to measure.Real-time detection of puller traction force by plate ring tension sensor, real-time displacement monitoring of puller sag of traction system by GNSS equipment, realize multi-point multi-parameter synchronous measurement, real-time stable and accurate acquisition of key parameters such as traction cable tension, puller traction force and traction cable sag at different positions to local area network, provide multi-source data basis for dynamic adjustment of traction system, realize efficient and stable traction of main cable.

Description

Technical Field

[0001] This invention belongs to the field of intelligent monitoring technology for the erection of main cables of suspension bridges, specifically relating to an intelligent mechanical monitoring system and method for a gantry-type main cable traction system. Background Technology

[0002] A suspension bridge, also known as a suspension bridge, is a bridge whose superstructure consists of cables or steel chains suspended from towers and anchored to both banks (or both ends of the bridge). The cables or steel chains are called the main cables, which are the lifeline of a suspension bridge.

[0003] There are two main construction techniques for erecting the main cable of a suspension bridge. One is the prefabricated parallel strand method, also known as the PPWS method, which involves prefabricating steel wires into parallel strands in a factory and then using a traction system to pull and erect them on the catwalk. The other is the aerial spinning method, also known as the AS method, which involves using a spinning wheel at the bridge site to reciprocate and pull steel wires to form the main cable strands.

[0004] The tension, traction force, and sag of the traction cable are crucial parameters in the operation of the main cable erection traction system. These parameters all change with the traction position. Excessive tension and traction force can overload the traction equipment, while insufficient tension and traction force can lead to excessive sag, posing a risk of collisions with equipment and personnel. Therefore, the traction system needs to achieve stable and accurate monitoring of these parameters during operation to guide dynamic adjustments of the traction equipment, ensuring construction safety and efficiency.

[0005] Currently, industry monitoring of traction systems only considers single-point structural stress, such as monitoring only a limited number of parameters like winch load and tension of the traction cables before and after the winch. There is no systematic, comprehensive monitoring method, allowing only a partial understanding of the stress or operation at a specific point in the traction system, without a complete grasp of the system's overall operational status. Furthermore, there is no precise method for measuring the wire rope tension in the traction system. Therefore, there is an urgent need for comprehensive intelligent monitoring of the traction system to guide the dynamic adjustment of traction system control commands and achieve efficient and stable traction of the main cable. Summary of the Invention

[0006] To address the technical problems existing in the prior art, this invention provides an intelligent mechanical monitoring system for a gantry-type main cable traction system, which can accurately measure parameters such as traction cable force, puller traction force, and traction cable sag.

[0007] Therefore, the technical solution provided by the present invention is as follows: An intelligent mechanical monitoring system for a gantry-type main cable traction system includes a pin shaft force sensor, a three-axis tilt sensor, a GNSS device, a plate ring tension sensor, a wireless signal collector, and a control system. The pin shaft force sensor, the three-axis tilt sensor, and the GNSS device are all electrically connected to the wireless signal collector, and the wireless signal collector and the control system are connected via a long optical fiber. The pin-shaft force sensor and the triaxial tilt sensor are used to measure the tension of the traction cable in real time. The plate ring tension sensor is used to measure the traction force of the puller. The GNSS device is used to monitor the displacement of the puller sag in the traction system. The wireless signal acquisition unit sends the traction cable tension, puller traction force, and puller sag data to the control system in real time. The control system compares these data with the set values ​​and sends control commands to the winch based on the comparison results, thereby adjusting the puller speed and the traction cable tension.

[0008] Furthermore, there are multiple pin-shaft force sensors, which are respectively installed on the cable saddle, the horizontal steering wheel installed at the entrance and exit of the traction system, the horizontal guide wheel of the winch, and the guide wheel assembly of the tower top gantry.

[0009] Furthermore, the tower top gantry guide wheel assembly is also equipped with a three-axis tilt sensor, which is used to collect the angles of the front and rear traction cables of the tower top gantry guide wheel assembly in real time.

[0010] Furthermore, the GNSS device is installed at the rear link of the puller to compare and calculate the original alignment of the traction cable with the actual spatial coordinates of the puller in real time.

[0011] Furthermore, the long optical fiber is laid on the catwalk, and one wireless signal collector is deployed every 100-120m.

[0012] The present invention also provides an intelligent mechanical monitoring method for a gantry-type main cable traction system. The method employs an intelligent mechanical monitoring system for the gantry-type main cable traction system, which uses a pin-shaft force sensor to measure the vertical pressure F of the traction cable on the guide wheel assembly in real time and a three-axis tilt sensor to measure the angles θ1 and θ2 between the front and rear traction cables and the horizontal line in real time, and calculates and corrects the tensions F1 and F2 of the front and rear traction cables in real time. The position of the traction device is determined by GNSS equipment, and the original shape of the traction cable is compared and calculated with the actual spatial coordinates of the traction device in real time. Based on satellite data processing algorithms, the sag of the traction cable under different traction positions is calculated. The wireless signal acquisition unit transmits the tension and sag data of the traction cable to the control system. The control system compares the received data with the set values ​​and sends control commands to the winch, thereby adjusting the speed of the puller and the tension of the traction cable until all data are within the set value range.

[0013] Furthermore, the tension of the front traction cable is F1 = Fsinθ1, and the tension of the rear traction cable is F2 = Fcosθ2.

[0014] The beneficial effects of this invention are: This invention achieves real-time correction and measurement of the tension of a flexible traction cable under swaying conditions by combining a pin-shaft force sensor and a triaxial tilt sensor, solving the problems of tension direction changes caused by different puller positions and the difficulty in measurement.

[0015] This invention utilizes a plate ring tension sensor to monitor the traction force of the puller in real time, ensuring it always operates within a safe load range and preventing breakage accidents caused by overload, thereby protecting the traction cable. This invention also uses GNSS equipment to monitor the sag of the puller in real time, ensuring sufficient safety space below the puller to avoid collisions with the catwalk below.

[0016] The method of this invention uses multi-point, multi-parameter synchronous measurement to stably and accurately collect key parameters such as traction cable tension, puller traction force, and traction cable sag at different locations to the local area network in real time, providing a multi-source data foundation for dynamically adjusting the traction system and realizing efficient and stable traction of the main cable. Attached Figure Description

[0017] Figure 1 This is a front view of a gantry-type main cable traction system; Figure 2 This is a schematic diagram showing the installation position of the pin-shaft force sensor in a gantry-type main cable traction system; Figure 3 This is a schematic diagram of the force on the guide wheel assembly pin shaft when there is no puller between the front and rear cat walkway gantry frames; Figure 4 This is a schematic diagram of the force on the guide wheel assembly pin shaft when there is a puller between the front and rear cat walkway masts; Figure 5 This is a flowchart of the detection method of the present invention.

[0018] In the diagram: 1. Traction cable; 2. Cable saddle; 3. Winch; 4. Tower top gantry; 5. Puller; 6. Catwalk gantry. Detailed Implementation

[0019] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0020] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided to fully and completely disclose the invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the drawings is not intended to limit the invention. In the drawings, the same units / elements are referred to by the same reference numerals.

[0021] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning. Example 1

[0022] This embodiment provides an intelligent mechanical monitoring system for a gantry-type main cable traction system, including a pin shaft force sensor, a three-axis tilt sensor, a GNSS device, a plate ring tension sensor, a wireless signal collector, and a control system. The pin shaft force sensor, the three-axis tilt sensor, and the GNSS device are all electrically connected to the wireless signal collector, and the wireless signal collector and the control system are connected via a long optical fiber. The pin-shaft force sensor and the triaxial tilt sensor are used to measure the tension of the traction cable 1 in real time. The plate ring tension sensor is used to measure the traction force of the puller 5. The GNSS device is used to monitor the displacement of the sag of the puller 5 in the traction system. The wireless signal acquisition unit sends the tension of the traction cable 1, the traction force of the puller 5, and the sag of the puller 5 to the control system in real time. The control system compares these data with the set values ​​and sends control commands to the winch 3 based on the comparison results, thereby adjusting the speed of the puller 5 and the tension of the traction cable 1.

[0023] This invention achieves real-time correction and measurement of the tension of the flexible traction cable 1 under swaying conditions by combining a pin-shaft force sensor and a triaxial tilt sensor, solving the problems of tension direction changes in the traction cable 1 caused by different positions of the puller 5 and the difficulty in measurement. Example 2

[0024] Based on Example 1, this example provides an intelligent mechanical monitoring system for a gantry-type main cable traction system. The pin-shaft force sensors are multiple and are respectively installed on the cable saddle 2, the horizontal steering wheel installed at the entrance and exit of the traction system, the horizontal guide wheel of the winch 3, and the guide wheel group of the tower top gantry 4.

[0025] The tower top gantry 4 guide wheel assembly is also equipped with a three-axis tilt sensor, which is used to collect the angle of the front and rear traction cables 1 of the tower top gantry 4 guide wheel assembly in real time.

[0026] In the gantry traction system, pins are replaced with pin-driven force sensors in each guide wheel assembly. Simultaneously, triaxial tilt sensors are installed on the guide wheel assembly structure to collect real-time data on the angle changes of the front and rear traction cables. The pin-driven force sensor operates based on mechanical principles such as Hooke's Law and the torsion law. Hooke's Law states that within the elastic range, the deformation of an object is directly proportional to the force acting on it. Therefore, when a force acts on the sensing element of the pin-driven force sensor, the sensing element deforms, thereby changing its resistance or capacitance. By measuring these changes in physical quantities, the magnitude of the force acting on the sensing element can be calculated.

[0027] In the suspension bridge tower top structure, when the traction device 5 is located on the left side of the tower top, the guide wheel assembly deflects to the left under the traction force; when the traction device 5 is located on the right side of the tower top, the guide wheel assembly deflects to the right accordingly, and the direction of deflection is always consistent with the installation position of the traction device 5. Because the angles of the two traction cables 1 are different, there is a deviation in the tension of the two traction cables 1. Adding a triaxial tilt sensor allows for a more accurate measurement of the tension of the two traction cables 1, building upon the traditional method of measuring the tension of the traction cables 1.

[0028] Gantry-type main cable traction system, such as Figure 1 As shown. In this embodiment, as Figure 2 As shown, six pin-shaft force sensors are installed at point A: four at the cable saddle 2 and two at the winch 3. Points B and C are both on the tower top gantry 4, each with four pin-shaft force sensors. One pin-shaft force sensor is installed on each of the two horizontal steering wheels at the traction system inlet and outlet. A total of 16 pin-shaft force sensors are present. The horizontal steering wheels are used to horizontally turn the cable strands from the direction coming from the catwalk, ensuring they are accurately aligned with the inlet channel of the cable saddle 2.

[0029] Since the angle of the traction cable 1 remains constant at the positions of the winch 3 and the cable saddle 2, the pin shaft force sensor is directly installed and measured. However, for the positions where the force angle of the traction cable 1 changes before and after the guide wheel assembly (such as the position of the tower top gantry 4, where the force angle of the traction cable 1 changes before and after the guide wheel assembly), the range and average value of the force angle change of the pin shaft of the guide wheel assembly are analyzed. The average value of this angle is used as the force installation direction of the pin shaft sensor, and an inclination sensor is installed on the guide wheel assembly for auxiliary correction. Example 3

[0030] Based on Embodiment 1, this embodiment provides an intelligent mechanical monitoring system for a gantry-type main cable traction system. The GNSS device is installed at the rear connecting rod position of the puller 5 to compare and calculate the original alignment of the traction cable 1 with the actual spatial position coordinates of the puller 5 in real time.

[0031] The sag of the traction device 5 is monitored using the GNSS Beidou positioning system. In the erection of the main cable of the suspension bridge, the traction device 5 is the core actuator and aerial work platform of the entire traction system. The traction device 5 is directly suspended from the traction cable 1 via pulleys or suspension points. Therefore, the vertical position of the traction device 5 depends primarily on the sag of the traction cable 1 at its location. The tension of the traction cable 1 controls both its sag and the sag of the traction device 5; as the tension of the traction cable 1 increases, the entire traction cable 1 is tightened, its sag decreases, and the traction device 5 is subsequently lifted, further reducing its sag. Therefore, monitoring the sag of the traction device 5 allows for the detection of the tension of the traction cable 1. Example 4

[0032] Based on Example 1, this example provides an intelligent mechanical monitoring system for a gantry-type main cable traction system. The long optical fiber is laid on the catwalk, and a wireless signal collector is deployed every 100-120m.

[0033] By laying a long optical fiber along the catwalk and installing a wireless signal collector every 100m, a local area network is formed to collect data from various sensors of the traction system in real time, including the tension of the traction cable 1 measured by the pin shaft sensor, the angle of the traction cable 1 before and after the tower top gantry 4, and the sag (spatial position) of the puller 5. Example 5

[0034] This embodiment provides an intelligent mechanical monitoring method for a gantry-type main cable traction system. The intelligent mechanical monitoring system of the gantry-type main cable traction system measures the vertical pressure F of the traction cable 1 on the guide wheel group in real time through a pin shaft force sensor and measures the angles θ1 and θ2 between the front and rear traction cables 1 and the horizontal line in real time through a three-axis tilt sensor. The tensions F1 and F2 of the front and rear traction cables 1 are calculated and corrected in real time. The position of the puller 5 is determined by GNSS equipment, and the original alignment of the traction cable 1 and the actual spatial position coordinates of the puller 5 are compared and calculated in real time. Based on satellite data processing algorithms, the sag of the traction cable 1 under different traction positions is calculated. The wireless signal acquisition device transmits the tension and sag data of the traction cable 1 to the control system. The control system compares the received data with the set values ​​and sends control commands to the winch 3, thereby adjusting the speed of the puller 5 and the tension of the traction cable 1 until all data are within the set value range.

[0035] like Figure 3 The diagram shows the force distribution of the catwalk gantry 6 system in an "unloaded" state (without the puller 5 and cable strands passing through). At this time, the lines connecting the fixed points of the guide wheel groups at the top of adjacent gantry frames have the same inclination angle everywhere, representing an "ideal unloaded reference state" with balanced internal forces and a smooth linear shape. All subsequent loading, operation, and monitoring will be performed with this state as the reference origin. Figure 3In the diagram, α is the angle between the line connecting the top of the nearest catwalk gantry 6 to the fixed point of the guide wheel assembly frame and the horizontal direction, T is the tension of the traction cable 1, and F is the direction of the sensor pressure.

[0036] Taking the traction process of the Huangniliangzi Bridge traction cable 1 as an example, the main bridge structure of the Huangniliangzi Bridge is a single-span 580-meter steel truss suspension bridge with a rise-to-span ratio of 1 / 10. The main cable is constructed using the PPWS method, and the main cable consists of 52 prefabricated parallel steel wire strands. The traction system is constructed with one set shared by upstream and downstream, arranged in a U-shape, with a total of two winches 3 and two pullers 5.

[0037] like Figure 4 The diagram shows the force on the guide wheel pin when there is a puller 5 between the front and rear cat walkway gantry 6. The force exerted by the traction cable 1 on the vertical guide wheel is F (kN), F1=F*sinθ1, F2=F*cosθ2. Example 6

[0038] Based on Example 5, this example provides an intelligent mechanical monitoring method for a gantry-type main cable traction system. Before the sensors monitor the traction data, such as... Figure 5 As shown, the sensor deployment steps are as follows: S1.1: Based on the location and quantity of equipment such as the gantry, winch 3, puller 5, and guide wheel assembly of the suspension bridge traction system, perform theoretical calculation and analysis of the tension of traction cable 1, clarify the trend of force and physical state change of the traction system, and determine the tension monitoring location of traction cable 1, tension monitoring range of puller 5, etc. S1.2: Determine the model of the position sensor for the gantry, puller 5, and traction cable 1 according to the monitoring requirements; S1.3: The tension of the traction cable 1 is indirectly measured using a pin sensor. For the traction cable 1 at a position where the force angle remains constant before and after the guide wheel assembly, the pin sensor is directly installed and measured. For the traction cable 1 at a position where the force angle changes before and after the guide wheel assembly, the range and average value of the force angle change of the pin of the guide wheel assembly are analyzed. The average value of this angle is taken as the force installation direction of the pin sensor. At the same time, an inclination sensor is installed on the guide wheel assembly for auxiliary correction. S1.4: The traction force of the puller 5 is directly measured by replacing the ear plate of the puller 5 with a plate ring tension sensor; S1.5: The sag of the puller 5 is monitored by the displacement of the GNSS Beidou positioning system. The GNSS Beidou positioning system is installed at the rear link of the puller 5. The original alignment of the traction cable 1 and the actual spatial position coordinates of the puller 5 are compared and calculated in real time. Based on the satellite data processing algorithm, the sag of the traction cable 1 under different traction positions is calculated. The satellite data processing algorithm is an existing technology. The real-time position of the puller 5 is obtained through GNSS and the data is preprocessed. Then, the spatial coordinates of the puller 5 are obtained by coordinate transformation of the starting anchor coordinates and the ending anchor coordinates. The actual sag is calculated and compared with the theoretical linearity. Finally, a safety assessment is carried out after the tension feedback of the traction cable 1. S1.6: A long optical fiber is laid along the catwalk, and a wireless signal collector is installed every 100m to form a local area network to collect traction system data in real time (including the tension of traction cable 1 measured by the pin sensor, the angle of traction cable 1 before and after the tower top gantry 4, and the spatial position of the puller 5). The data is transmitted to the control system, which dynamically adjusts the traction system's operating commands based on theoretical calculations and on-site conditions. The tensions F1 and F2 of the front and rear traction cables 1 are determined based on the different angles of the gantry 4 at the top of the tower and the tension F measured by the pin sensor. Based on the comparison of different tensions in the traction cables 1 and the sag monitoring data of the traction cables 1, the speed of the puller 5 and the commands of the winch 3 are adjusted.

[0039] This invention combines the layout of the suspension bridge main cable erection traction system with the application of Internet of Things sensors to stably and accurately measure key mechanical parameters such as the puller tension and traction cable tension during the entire traction process, providing data support for the dynamic adjustment of traction equipment to ensure construction safety and efficiency.

[0040] The above examples are merely illustrative of the present invention and do not constitute a limitation on the scope of protection of the present invention. All designs that are the same as or similar to the present invention are within the scope of protection of the present invention.

Claims

1. An intelligent mechanical monitoring system for a gantry-type main cable traction system, characterized in that: It includes a pin-shaft force sensor, a three-axis tilt sensor, a GNSS device, a plate ring tension sensor, a wireless signal collector, and a control system. The pin-shaft force sensor, the three-axis tilt sensor, and the GNSS device are all electrically connected to the wireless signal collector, and the wireless signal collector and the control system are connected via a long optical fiber. The pin-shaft force sensor and the triaxial tilt sensor are used to measure the tension of the traction cable in real time. The plate ring tension sensor is used to measure the traction force of the puller. The GNSS device is used to monitor the displacement of the puller sag in the traction system. The wireless signal acquisition unit sends the traction cable tension, puller traction force, and puller sag data to the control system in real time. The control system compares these data with the set values ​​and sends control commands to the winch based on the comparison results, thereby adjusting the puller speed and the traction cable tension.

2. The intelligent mechanical monitoring system for a gantry-type main cable traction system according to claim 1, characterized in that: The pin-shaft force sensors are multiple and are respectively installed on the cable saddle, the horizontal steering wheel installed at the entrance and exit of the traction system, the horizontal guide wheel of the winch, and the guide wheel group of the tower top gantry.

3. The intelligent mechanical monitoring system for a gantry-type main cable traction system according to claim 2, characterized in that: The tower top gantry guide wheel assembly is also equipped with a three-axis tilt sensor, which is used to collect the angles of the front and rear traction cables of the tower top gantry guide wheel assembly in real time.

4. The intelligent mechanical monitoring system for a gantry-type main cable traction system according to claim 1, characterized in that: The GNSS device is installed at the rear link of the puller to compare and calculate the original alignment of the traction cable with the actual spatial coordinates of the puller in real time.

5. The intelligent mechanical monitoring system for a gantry-type main cable traction system according to claim 1, characterized in that: The long optical fiber is laid on the catwalk, and the wireless signal collector is deployed every 100-120m.

6. An intelligent mechanical monitoring method for a gantry-type main cable traction system, employing the intelligent mechanical monitoring system for a gantry-type main cable traction system as described in any one of claims 1-5, characterized in that: The vertical pressure F of the traction cable on the guide wheel assembly is measured in real time by the pin-shaft force sensor, and the angles θ1 and θ2 between the front and rear traction cables and the horizontal line are measured in real time by the triaxial tilt sensor. The tensions F1 and F2 of the front and rear traction cables are calculated and corrected in real time. The position of the traction device is determined by GNSS equipment, and the original shape of the traction cable is compared and calculated with the actual spatial coordinates of the traction device in real time. Based on satellite data processing algorithms, the sag of the traction cable under different traction positions is calculated. The wireless signal acquisition unit transmits the tension and sag data of the traction cable to the control system. The control system compares the received data with the set values ​​and sends control commands to the winch, thereby adjusting the speed of the puller and the tension of the traction cable until all data are within the set value range.

7. The intelligent mechanical monitoring method for a gantry-type main cable traction system according to claim 6, characterized in that: The tension of the front traction cable is F1 = Fsinθ1, and the tension of the rear traction cable is F2 = Fcosθ2.

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