A method and system for detecting overload and service life of a hoisting machine

Abstract

This invention discloses a method and system for detecting overload and lifespan of lifting machinery, relating to the field of crane safety monitoring technology. The method includes: collecting multi-source monitoring data during the operation of the lifting machinery and preprocessing it; constructing a load fusion model to calculate the equivalent load and comparing it with a preset rated load threshold to obtain the load utilization rate and determine whether overload has occurred; calculating the stress response of the key structure of the lifting machinery; calculating the cumulative fatigue damage value of the key structure based on the stress response and historical load cycle data; predicting the remaining service life of the key structure of the lifting machinery; if overload is detected or the remaining service life is lower than the preset threshold, outputting an early warning signal and triggering load limiting or shutdown control; storing the monitoring data, calculation results, and early warning information, and supporting remote access and operation and maintenance management. This application can dynamically judge based on the stress conditions during actual operation, thereby more accurately reflecting the degree of equipment wear and tear.

Description

Technical Field

[0001] This invention relates to the field of crane safety monitoring technology, specifically to a method and system for detecting overload and lifespan of crane machinery. Background Technology

[0002] Lifting machinery, as key equipment in construction, port loading and unloading, and industrial production, mainly includes tower cranes, bridge cranes, and gantry cranes. Its operational safety directly affects personnel safety and project progress. In actual use, lifting machinery typically operates under complex conditions, affected by changes in the load being lifted, as well as the combined effects of wind loads, equipment movement, and structural deformation. Therefore, its stress state exhibits significant dynamics and uncertainties.

[0003] Currently, monitoring methods for the safe operation of lifting machinery mainly focus on two aspects: overload protection and structural safety assessment. Regarding overload protection, existing technologies typically monitor the lifted load using load sensors or torque limiters and compare it to the rated load. When the load exceeds a set threshold, an alarm is triggered or load-limiting measures are implemented. However, these methods mostly rely on a single lifted load or simple torque calculations for judgment, failing to fully consider the influence of factors such as wind speed changes, equipment acceleration and deceleration, and the actual stress state of the structure. In complex operating conditions, this can easily lead to misjudgments or omissions, making it difficult to accurately reflect the true stress level of the equipment. Regarding structural safety assessment, existing technologies largely rely on periodic manual inspections or experience-based judgments, visually inspecting or performing simple checks on key structural components. This approach typically uses fixed time intervals, lacking a dynamic reflection of the actual operating status of the equipment, making it difficult to promptly detect fatigue damage that occurs during long-term operation. Furthermore, because the loads borne by lifting machinery vary significantly under different operating conditions, simply relying on maintenance cycles cannot accurately assess the actual wear and tear on the structure, posing safety hazards.

[0004] Furthermore, while some existing technologies attempt to introduce strain monitoring or data acquisition methods, in practical applications, various types of data are often analyzed independently. For example, load weight is used for overload judgment, and strain is used for local monitoring. The lack of a unified data processing method and correlation analysis mechanism results in a lack of effective connection between various monitoring results, making it impossible to form a comprehensive evaluation of the equipment's operating status. This fragmented use of data means that the data collected in the early stages is not fully utilized, reducing the overall effectiveness of the monitoring system.

[0005] In summary, existing technologies for safety monitoring of lifting machinery have at least the following shortcomings: First, overload judgment relies on a single parameter, which is difficult to adapt to complex working conditions; second, structural life assessment mainly relies on manual experience or fixed cycles, lacking dynamic analysis capabilities; and third, there is a lack of unified processing and correlation application among multi-source monitoring data, making it difficult to comprehensively reflect the operating status of the equipment. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method and system for detecting overload and lifespan of lifting machinery.

[0007] The objective of this invention is achieved through the following technical solution:

[0008] In a first aspect, this application discloses a method for detecting overload and lifespan of lifting machinery, comprising the following steps:

[0009] S1. Collect multi-source monitoring data during the operation of the lifting machinery and preprocess it. The multi-source monitoring data includes load data, structural strain data, tilt angle data, wind speed data, displacement data, and work cycle data.

[0010] S2. Construct a load fusion model using preprocessed multi-source monitoring data, and calculate the equivalent load of the lifting machinery under the current working conditions; then compare the equivalent load with a preset rated load threshold to obtain the load utilization rate and determine whether overload has occurred.

[0011] S3. Calculate the stress response of the key structure of the lifting machinery based on the equivalent load and structural parameters; calculate the cumulative fatigue damage value of the key structure based on the stress response and historical load cycle data; the key structure includes the main boom and connecting nodes.

[0012] S4. Based on the design life parameters of the lifting machinery and the cumulative fatigue damage value, predict the remaining service life of the key structures of the lifting machinery; if overload or remaining service life is detected below a preset threshold, output a warning signal and trigger load limiting or shutdown control.

[0013] S5 stores monitoring data, calculation results, and early warning information, and supports remote access and operation and maintenance management.

[0014] Based on the first aspect, the preprocessing of multi-source monitoring data in step S1 specifically includes: using moving average or low-pass filtering to filter the multi-source monitoring data to eliminate interference from environmental vibration and electrical noise; then, aligning the timestamps of the filtered multi-source monitoring data so that monitoring data from different sources can be uniformly calculated on the same time scale.

[0015] Based on the first aspect, step S2 involves a unified transformation of all factors affecting the stress on the lifting machinery, specifically including:

[0016] For the lifting weight data, use the formula Calculate the force generated by the suspended weight ,in, Indicates the weight of the load being lifted. Represents gravitational acceleration;

[0017] Through formula Calculate the wind load corresponding to the wind speed ,in, Indicates air density, Indicates the drag coefficient. Indicates the area exposed to wind. Indicates wind speed;

[0018] Through displacement data Calculate acceleration , Further through formula Calculate inertial loads ,in, Indicates equivalent quality.

[0019] Based on the first aspect, step S2 specifically includes: based on the force generated by the suspended weight. Wind load and inertial load Construct equivalent load , ,in, Indicates the force generated by the lifting weight The weighting coefficients, Indicates wind load The weighting coefficients, Indicates inertial load The weighting coefficients, and .

[0020] Based on the first aspect, step S2 further includes: calculating the ratio of the equivalent load to the equipment's rated load, i.e. ,in, Indicates load utilization rate. This represents the force corresponding to the rated load, based on the load utilization rate. The operating status of lifting machinery is divided into normal, warning, and overload by the warning coefficient.

[0021] Based on the first aspect, step S3 specifically includes:

[0022] The key structure primarily bears bending forces, as determined by the formula... Calculate bending moment ,in, The length of the lever arm is indicated, and then the stress is calculated based on the structural section parameters. , ,in, This represents the distance from the neutral axis of the cross section to the edge. Represents the moment of inertia of the cross section;

[0023] The obtained stress time history was statistically analyzed cyclically, and different stress amplitudes were extracted using the rainflow counting method. and its corresponding number of iterations Based on the material fatigue characteristics, the fatigue life relationship is expressed using SN curves. ,in, Indicates the stress amplitude The allowed number of loops, Indicates the material constant; Indicates the fatigue index of a material;

[0024] Based on Miner's linear cumulative damage theory, through the formula Calculate cumulative fatigue damage ,in; The stress level is then used; subsequently, the load utilization rate is introduced as an effect on cumulative fatigue damage. Make corrections, that is ,in, This indicates the corrected cumulative fatigue damage.

[0025] Based on the first aspect, step S4 specifically includes: based on the corrected cumulative fatigue damage Through formula Calculate the remaining service life of critical structures of lifting machinery ,in, Indicates design life parameters; overall load utilization rate With the corrected cumulative fatigue damage Make a judgment; if the conditions are met... or If this occurs, a warning is triggered, alerting the operator via audible and visual alarms, and a signal is sent to the control unit to execute load limiting or shutdown operations. This indicates the damage warning threshold.

[0026] Secondly, this application discloses a crane overload and lifespan detection system, which utilizes the aforementioned crane overload and lifespan detection method, including:

[0027] The data acquisition module is used to collect multi-source monitoring data during the operation of lifting machinery;

[0028] The data preprocessing module is used to preprocess the multi-source monitoring data;

[0029] The equivalent load calculation module is used to construct a load fusion model based on preprocessed multi-source monitoring data and calculate the equivalent load of the lifting machinery under the current working conditions.

[0030] An overload detection module is used to compare the equivalent load with a preset rated load threshold to obtain the load utilization rate and determine whether an overload has occurred.

[0031] The structural stress calculation module is used to calculate the stress response of key structural parts of the lifting machinery based on the equivalent load and structural parameters.

[0032] The fatigue damage assessment module is used to calculate the cumulative fatigue damage value of the structure based on the stress response and historical load cycle data.

[0033] The remaining service life prediction module is used to predict the remaining service life of key structures of lifting machinery based on the cumulative fatigue damage value and the design service life parameters.

[0034] The early warning and control module is used to output an early warning signal and trigger load limiting or shutdown control when overload or remaining life is detected to be below a preset threshold.

[0035] The data storage and remote monitoring module is used to store monitoring data, calculation results and early warning information, and supports remote access and operation and maintenance management.

[0036] The beneficial effects of this invention are:

[0037] 1) This application unifies the multi-source monitoring information such as load, wind speed and equipment operating status, and transforms it into an equivalent load that can reflect the actual stress situation. Compared with the traditional method of judging based solely on load or torque, it can more realistically reflect the stress state of lifting machinery under complex working conditions, thereby improving the accuracy of overload detection and reducing misjudgment and omission.

[0038] 2) This application further transforms the equivalent load into the stress response of key structural parts, and combines the material fatigue characteristics to conduct quantitative analysis of structural damage. This makes structural safety assessment no longer dependent on human experience or fixed maintenance cycles, but can be dynamically judged based on the stress situation during actual operation, thereby more accurately reflecting the degree of equipment wear and tear and helping to discover potential safety hazards in advance.

[0039] 3) This application integrates the overload detection results with the structural damage assessment results to estimate the remaining service life in real time during equipment operation and issue timely warnings when overload or damage approaches the threshold. At the same time, it can link the control system to perform load limiting or shutdown operations, thereby improving the safety assurance capability of equipment operation. Furthermore, it achieves centralized management of operation information through data storage and remote monitoring modules, which facilitates equipment maintenance and management decisions. Attached Figure Description

[0040] Figure 1 This is a schematic diagram illustrating the steps of a method for detecting overload and lifespan of lifting machinery according to an embodiment of the present invention;

[0041] Figure 2 This is a schematic diagram of a crane overload and life detection system according to an embodiment of the present invention. Detailed Implementation

[0042] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0043] For example, this application discloses a method for detecting overload and lifespan of lifting machinery, the steps of which are illustrated in the following diagram. Figure 1 As shown, it includes the following steps:

[0044] S1. Collect multi-source monitoring data during the operation of the lifting machinery and preprocess it. The multi-source monitoring data includes load data, structural strain data, tilt angle data, wind speed data, displacement data, and work cycle data.

[0045] S2. Construct a load fusion model using preprocessed multi-source monitoring data, and calculate the equivalent load of the lifting machinery under the current working conditions; then compare the equivalent load with a preset rated load threshold to obtain the load utilization rate and determine whether overload has occurred.

[0046] S3. Calculate the stress response of the key structure of the lifting machinery based on the equivalent load and structural parameters; calculate the cumulative fatigue damage value of the key structure based on the stress response and historical load cycle data; the key structure includes the main boom and connecting nodes.

[0047] S4. Based on the design life parameters of the lifting machinery and the cumulative fatigue damage value, predict the remaining service life of the key structures of the lifting machinery; if overload or remaining service life is detected below a preset threshold, output a warning signal and trigger load limiting or shutdown control.

[0048] S5 stores monitoring data, calculation results, and early warning information, and supports remote access and operation and maintenance management.

[0049] For example, taking a tower crane as an example, a load sensor is installed at the hook to obtain the lifting weight information; strain sensors are arranged at the root of the main boom and key connection nodes of the tower body to reflect the stress state of the structure; a wind speed sensor is installed at an unobstructed position on the top of the crane; at the same time, the displacement and rotational motion data of the trolley are obtained through encoders or displacement sensors, and the attitude information is obtained through tilt sensors. The above sensors collect the operation data in real time and uniformly add timestamps to form the original multi-source monitoring data.

[0050] For example, the preprocessing of multi-source monitoring data in step S1 specifically includes: filtering the multi-source monitoring data using methods such as moving average or low-pass filtering to eliminate interference from environmental vibration and electrical noise; then, aligning the timestamps of the filtered multi-source monitoring data so that monitoring data from different sources can be calculated uniformly on the same time scale. After processing, stable and synchronized time-series data are obtained, providing a reliable foundation for subsequent analysis.

[0051] For example, instead of directly using a single load for judgment, step S2 unifies and transforms all factors affecting the force on the lifting machinery to establish a unified physical basis, specifically including:

[0052] For the lifting weight data, use the formula Calculate the force generated by the suspended weight (Unit: Newtons (N)), where, Indicates the weight of the load being lifted (in kilograms). Represents gravitational acceleration;

[0053] Through formula Calculate the wind load corresponding to the wind speed (Unit: Newtons (N)), where, Air density (unit: ) ), This represents the drag coefficient (dimensionless). Represents the windward area (unit: m²). 2 ), Wind speed is indicated (unit: m / s).

[0054] Through displacement data Calculate acceleration (unit: m) (Unit: m / ) ), Further through formula Calculate inertial loads (Unit: Newtons (N)), where, This represents the equivalent mass (in kilograms). Through the above steps, all external influences are uniformly converted into the common dimension of force.

[0055] For example, step S2 specifically includes: based on the force generated by the suspended weight. Wind load and inertial load Construct equivalent load (Unit: Newtons (N)) ,in, Indicates the force generated by the lifting weight The weighting coefficient (dimensionless). Indicates wind load The weighting coefficient (dimensionless). Indicates inertial load The weighting coefficients (dimensionless), and .

[0056] For example, step S2 further includes: calculating the ratio of the equivalent load to the rated load of the equipment, i.e. ,in, This represents the load utilization rate (dimensionless), which is used not only for real-time alarms but also for correction calculations in subsequent life assessments. This represents the force corresponding to the rated load, based on the load utilization rate. The operating status of lifting machinery is divided into normal, warning, and overload states by the early warning coefficient and load utilization rate. The equipment operating status is divided into several categories, including: when When the equipment is in normal operating condition, it is determined that the equipment is in normal operating condition; when When the device is in a warning state, it is determined that the device is in an early warning state; when When this occurs, the equipment is determined to be in an overload state. The coefficient 0.9 is a warning factor used to identify operating conditions approaching the rated load in advance, thus allowing operators sufficient time for a safe response.

[0057] For example, the equivalent load is further converted into a structural response, and step S3 specifically includes:

[0058] The key structure primarily bears bending forces, as determined by the formula... Calculate bending moment (Unit: N·m), where, The lever arm length (in meters) is then used to calculate the stress based on the structural section parameters. (Unit: Pa) ,in, This represents the distance from the neutral axis of the cross section to the edge (in meters). Moment of inertia of cross section (unit: This completes the conversion from load to structural stress, providing fundamental data for fatigue analysis.

[0059] The obtained stress time history was statistically analyzed cyclically, and different stress amplitudes were extracted using the rainflow counting method. (Unit: Pa) and its corresponding number of cycles Based on the material fatigue characteristics, the fatigue life relationship is expressed using SN curves. ,in, Indicates the stress amplitude The allowed number of loops (in cycles). Indicates the material constant; Indicates the fatigue index of a material;

[0060] Based on Miner's linear cumulative damage theory, through the formula Calculate cumulative fatigue damage (dimensionless), where; The cumulative fatigue damage is the stress level number. It directly reflects the degree of structural damage; in order to reflect the impact of overload on structural life, the effect of load utilization rate on cumulative fatigue damage is then introduced. Make corrections, that is ,in, It represents the corrected cumulative fatigue damage (dimensionless); it enables feedback of overload test results to life assessment.

[0061] For example, step S4 specifically includes: based on the corrected cumulative fatigue damage Through formula Calculate the remaining service life of critical structures of lifting machinery (Units are seconds (s) or hours (h), where, Indicates design life parameters (unit: time in seconds or hours); overall load utilization rate With the corrected cumulative fatigue damage Make a judgment; if the conditions are met... or If this occurs, a warning is triggered, alerting the operator via audible and visual alarms, and a signal is sent to the control unit to execute load limiting or shutdown operations. This indicates the damage warning threshold.

[0062] For example, this application discloses an overload and life detection system for lifting machinery, the structural schematic diagram of which is shown below. Figure 2 As shown, the above-described method for detecting overload and lifespan of lifting machinery includes:

[0063] The data acquisition module is used to collect multi-source monitoring data during the operation of lifting machinery;

[0064] The data preprocessing module is used to preprocess the multi-source monitoring data;

[0065] The equivalent load calculation module is used to construct a load fusion model based on preprocessed multi-source monitoring data and calculate the equivalent load of the lifting machinery under the current working conditions.

[0066] An overload detection module is used to compare the equivalent load with a preset rated load threshold to obtain the load utilization rate and determine whether an overload has occurred.

[0067] The structural stress calculation module is used to calculate the stress response of key structural parts of the lifting machinery based on the equivalent load and structural parameters.

[0068] The fatigue damage assessment module is used to calculate the cumulative fatigue damage value of the structure based on the stress response and historical load cycle data.

[0069] The remaining service life prediction module is used to predict the remaining service life of key structures of lifting machinery based on the cumulative fatigue damage value and the design service life parameters.

[0070] The early warning and control module is used to output an early warning signal and trigger load limiting or shutdown control when overload or remaining life is detected to be below a preset threshold.

[0071] The data storage and remote monitoring module is used to store monitoring data, calculation results and early warning information, and supports remote access and operation and maintenance management;

[0072] For example, taking a tower crane used on a construction site as an example, the data acquisition module first acquires on-site operational information. Specifically, a load sensor is installed at the hook to collect the weight information of the hoisted object; strain sensors are arranged at the root of the main boom and the connection nodes of the tower body to reflect changes in structural stress; a wind speed sensor is installed at an unobstructed location on the top of the tower crane to obtain the ambient wind speed; simultaneously, the trolley's displacement and rotation status are acquired through the equipment's built-in encoder or additional displacement sensors, and the equipment's attitude information is acquired through a tilt sensor. The above sensors continuously output data, forming multi-source monitoring data, which is then transmitted to subsequent modules for processing.

[0073] After the data enters the data preprocessing module, it is first filtered to eliminate the noise caused by factors such as construction environment vibration and electromagnetic interference, and to remove abnormal fluctuation data. Then, the data from different sources are aligned according to the timestamp so that the data of various types have a corresponding relationship at the same time point, thereby obtaining a stable and synchronous data sequence, which provides a reliable basis for subsequent calculations.

[0074] The preprocessed data is then fed into the equivalent load calculation module. In this module, the load information, wind speed information, and equipment motion state are comprehensively considered. Through a unified transformation method, the influences from different sources are uniformly represented as the combined action borne by the structure. Based on the structural characteristics of the equipment, each influencing factor is weighted to obtain an equivalent load value that reflects the current operating conditions. This equivalent load serves as the primary basis for subsequent analysis and is continuously used in multiple modules.

[0075] Subsequently, the equivalent load is input to the overload detection module. In this module, the current operating status is determined by comparing the equivalent load with the equipment's rated load capacity, and is categorized as normal, near-overload, or overload. When near-overload or reaching the overload threshold is detected, the system records the corresponding status information and transmits the result to the subsequent analysis module for further assessment of equipment operating risks.

[0076] In the structural stress calculation module, based on the equivalent load and the structural parameters of the lifting machinery, the load action is converted into the stress conditions of key components such as the main boom and connecting nodes, thereby obtaining the stress changes at these locations under the current operating conditions. This module realizes the transformation from load information to structural response information, and its output results are directly used as input for fatigue analysis.

[0077] The fatigue damage assessment module performs statistical processing on structural stress. Specifically, it analyzes stress changes over a period of time, summarizes the complex stress change process into different levels of cyclic loads and their occurrence frequency, and combines this with the fatigue characteristics of the material to assess the degree of damage to the structure in the current operating stage, obtaining damage indicators that reflect the wear and tear of the structure.

[0078] In this embodiment, to make the evaluation results more consistent with actual operating conditions, the fatigue damage evaluation module also adjusts the calculation of damage based on the judgment results of the overload detection module. When the equipment operates under high load or near overload conditions for a long period of time, the damage results are corrected accordingly, so that the evaluation results not only reflect the number of cycles, but also reflect the impact of the load level on structural damage.

[0079] Subsequently, the corrected damage results are input into the remaining service life prediction module. This module estimates the remaining usable time of the structure based on the relationship between the current damage level and the equipment's design life, and outputs a continuously updated service life prediction result to reflect the current service status of the equipment.

[0080] In the early warning and control module, the system comprehensively assesses overload detection results and lifespan prediction results. When overload is detected or structural damage approaches a preset threshold, the system triggers an early warning, alerting operators with audible and visual alarms and simultaneously sending the warning information to the control system. If necessary, the control module can perform operations such as load limiting, speed reduction, or shutdown to mitigate operational risks.

[0081] Meanwhile, all monitoring data, analysis results, and early warning information are transmitted to the data storage and remote monitoring module for storage and management. Administrators can view the equipment's operating status, historical data, and lifespan changes in real time through the remote monitoring platform, enabling centralized monitoring and maintenance management of the equipment.

[0082] As can be seen from the above implementation process, in this embodiment, the modules are connected step by step according to the data processing order, and the output of the previous module serves as the input of the next module, so that each link from data acquisition to status assessment to risk warning can run continuously, thereby realizing a comprehensive analysis of the operating status and structural life of the lifting machinery.

[0083] The above description is merely a preferred embodiment of the present invention. It should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the concept described herein through the above teachings or related technologies or knowledge. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A method for detecting overload and service life of a hoisting machine, characterized by, Includes the following steps: S1. Collect multi-source monitoring data during the operation of the lifting machinery and preprocess it. The multi-source monitoring data includes load data, structural strain data, tilt angle data, wind speed data, displacement data, and work cycle data. S2. Construct a load fusion model using preprocessed multi-source monitoring data, and calculate the equivalent load of the lifting machinery under the current working conditions; then compare the equivalent load with a preset rated load threshold to obtain the load utilization rate and determine whether overload has occurred. S3. Calculate the stress response of the key structure of the lifting machinery based on the equivalent load and structural parameters; calculate the cumulative fatigue damage value of the key structure based on the stress response and historical load cycle data; the key structure includes the main boom and connecting nodes. S4. Based on the design life parameters of the lifting machinery and the cumulative fatigue damage value, predict the remaining service life of the key structures of the lifting machinery; if overload or remaining service life is detected below a preset threshold, output a warning signal and trigger load limiting or shutdown control. S5 stores monitoring data, calculation results, and early warning information, and supports remote access and operation and maintenance management.

2. The method of claim 1, wherein, The preprocessing of multi-source monitoring data in step S1 specifically includes: filtering the multi-source monitoring data using moving average or low-pass filtering to eliminate interference from environmental vibration and electrical noise; then, aligning the timestamps of the filtered multi-source monitoring data so that monitoring data from different sources can be calculated uniformly on the same time scale.

3. The method for detecting overload and lifespan of lifting machinery according to claim 2, characterized in that, Step S2 involves uniformly transforming all factors affecting the force on the lifting machinery, specifically including: For the lifting weight data, use the formula Calculate the force generated by the suspended weight ,in, Indicates the weight of the load being lifted. Represents gravitational acceleration; Through formula Calculate the wind load corresponding to the wind speed ,in, Indicates air density, Indicates the drag coefficient. Indicates the area exposed to wind. Indicates wind speed; Through displacement data Calculate acceleration , Further through formula Calculate inertial loads ,in, Indicates equivalent quality.

4. The method for detecting overload and lifespan of lifting machinery according to claim 3, characterized in that, Step S2 specifically includes: the force generated by the suspended weight. Wind load and inertial load Construct equivalent load , ,in, Indicates the force generated by the lifting weight The weighting coefficients, Indicates wind load The weighting coefficients, Indicating inertial load The weighting coefficients, and .

5. The method for detecting overload and lifespan of lifting machinery according to claim 4, characterized in that, Step S2 further includes: calculating the ratio of the equivalent load to the equipment's rated load, i.e. ,in, Indicates load utilization rate. This represents the force corresponding to the rated load, based on the load utilization rate. The operating status of lifting machinery is divided into normal, warning, and overload by the warning coefficient.

6. The method for detecting overload and lifespan of lifting machinery according to claim 5, characterized in that, Step S3 specifically includes: The key structure primarily bears bending forces, as determined by the formula... Calculate bending moment ,in, The length of the lever arm is indicated, and then the stress is calculated based on the structural section parameters. , ,in, This represents the distance from the neutral axis of the cross section to the edge. Represents the moment of inertia of the cross section; The obtained stress time history was statistically analyzed cyclically, and different stress amplitudes were extracted using the rainflow counting method. and its corresponding number of iterations Based on the material fatigue characteristics, the fatigue life relationship is expressed using SN curves. ,in, Indicates the stress amplitude The allowed number of loops, Indicates the material constant; Indicates the fatigue index of a material; Based on Miner's linear cumulative damage theory, through the formula Calculate cumulative fatigue damage ,in; The stress level is then used; subsequently, the load utilization rate is introduced as an effect on cumulative fatigue damage. Make corrections, that is ,in, This indicates the corrected cumulative fatigue damage.

7. The method for detecting overload and lifespan of lifting machinery according to claim 6, characterized in that, Step S4 specifically includes: based on the corrected cumulative fatigue damage Through formula Calculate the remaining service life of critical structures of lifting machinery ,in, Indicates design life parameters; overall load utilization rate With the corrected cumulative fatigue damage Make a judgment; if the conditions are met... or If this occurs, a warning is triggered, alerting the operator via audible and visual alarms, and a signal is sent to the control unit to execute load limiting or shutdown operations. This indicates the damage warning threshold.

8. A lifting machinery overload and life detection system, employing the lifting machinery overload and life detection method according to any one of claims 1-7, characterized in that, include: The data acquisition module is used to collect multi-source monitoring data during the operation of lifting machinery; The data preprocessing module is used to preprocess the multi-source monitoring data; The equivalent load calculation module is used to construct a load fusion model based on preprocessed multi-source monitoring data and calculate the equivalent load of the lifting machinery under the current working conditions. An overload detection module is used to compare the equivalent load with a preset rated load threshold to obtain the load utilization rate and determine whether an overload has occurred. The structural stress calculation module is used to calculate the stress response of key structural parts of the lifting machinery based on the equivalent load and structural parameters. The fatigue damage assessment module is used to calculate the cumulative fatigue damage value of the structure based on the stress response and historical load cycle data. The remaining service life prediction module is used to predict the remaining service life of key structures of lifting machinery based on the cumulative fatigue damage value and the design service life parameters. The early warning and control module is used to output an early warning signal and trigger load limiting or shutdown control when overload or remaining life is detected to be below a preset threshold. The data storage and remote monitoring module is used to store monitoring data, calculation results and early warning information, and supports remote access and operation and maintenance management.

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