Fault detection, structure optimization method and device based on turnover plate machine prediction power consumption

Abstract

This invention provides a fault detection and structural optimization method and apparatus based on predicted power consumption of a flipping machine. The method includes: acquiring equipment parameters and load parameters of the load steel plate during the flipping process; obtaining the output torque of the left and right mechanism reducers of the flipping machine based on the equipment and load parameters; obtaining the predicted power consumption of the flipping machine within one flipping cycle based on the output torque of the left and right mechanism reducers; comparing the predicted power consumption with the measured power consumption, and determining whether the flipping machine's motor has a fault based on the comparison result. This invention provides a way to accurately determine whether the equipment has abnormal conditions such as mechanical wear, decreased transmission efficiency, or changes in structural parameters by comparing the deviation between actual and theoretical power consumption. Furthermore, this application can provide a reference for selecting flipping machine motors, significantly reducing energy consumption and saving production costs.

Description

Technical Field

[0001] This invention relates to the field of thick plate production technology, and in particular to a fault detection and structural optimization method and device based on the predicted power consumption of a flipping machine. Background Technology

[0002] Tilting machines are indispensable equipment in the finishing process of medium and heavy plate workshops. They typically employ a double-arm crank-rocker type structure, using two sets of crank-rocker mechanisms to drive the tilting arms and achieve the flipping operation of steel plates. Currently, tilting machines are widely used in industrial settings. However, with increasingly stringent requirements for energy conservation, emission reduction, and equipment reliability, the need for optimized design and fault diagnosis of tilting machines is becoming increasingly prominent.

[0003] Currently, research on flipping machines mainly focuses on structural design optimization, kinematic analysis, and dynamic simulation. For example, Wang Yongqin's "Computer-Aided Optimization Design of Crank-Rocker Type Flipping Machine" primarily considers the influence of multiple parameters on this type of flipping machine mechanism to determine the optimal design scheme and develops complete software. Guo Hong's "Solving the Motion Trajectory of a Double-Arm Crank-Rocker Type Flipping Machine Using Mathcad" mainly utilizes Mathcad software and employs analytical methods to analyze and solve the motion trajectory of the flipping machine, accurately calculating the motion trajectory parameters of the flipping machine's flipping of the steel plate, and realizing the optimized design of the flipping machine's mechanism. Jia Jingzhen's "Optimization Design of a Double-Arm Crank-Rocker Type Flipping Machine" mainly analyzes the structural composition and working principle of a double-arm crank-rocker type flipping machine, uses the constrained coordinate rotation method to establish an objective function, and optimizes the main parameters such as the transmission angle, rod dimensions, and included angle of the flipping mechanism and the connecting mechanism. Liu Yun's "Design of Extra-Thick Plate Tilting Machine" primarily utilizes computer-aided dynamic simulation models to perform extensive calculations, fully simulating the machine's motion and obtaining the system's input torque curve. Liu Ge's "Design and Simulation of Medium-Thick Plate Tilting Machine" employs analytical methods to initially determine the parameters of the tilting machine mechanism, then uses software to perform motion simulations. Based on the simulation results, the model parameters are further modified, and simulations are repeated to finally obtain a set of optimal mechanism parameters, thus completing the structural design of the tilting machine.

[0004] However, the above methods still have the following shortcomings: the existing technologies mainly focus on the motion characteristics design or trajectory optimization of the flipping mechanism, but do not conduct in-depth research on the theoretical calculation methods of the operating power consumption of the flipping machine and the key influencing factors of energy consumption. The existing technologies do not combine the predicted results of the operating power consumption of the flipping machine for fault diagnosis and structural optimization, nor do they reveal potential equipment operation hazards through abnormal energy consumption.

[0005] Therefore, there is an urgent need for a fault detection and structural optimization method and device based on the predicted power consumption of the flipping machine. This method can realize fault detection and equipment structure optimization based on the accurate prediction of the dynamic power consumption of the flipping process, thereby improving the operating efficiency and energy saving level of the flipping machine and meeting the needs of modern industrial production for high-efficiency and low-consumption equipment. Summary of the Invention

[0006] In view of this, the present invention provides a fault detection and structural optimization method and apparatus based on the predicted power consumption of a flip-board machine, in order to solve at least one of the aforementioned problems.

[0007] To achieve the above objectives, the present invention adopts the following solution:

[0008] According to a first aspect of the present invention, a fault detection method based on predicted power consumption of a flipping machine is provided. The method includes: acquiring equipment parameters of the flipping machine during the flipping process and load parameters of the load steel plate; obtaining the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters; obtaining the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer; comparing the predicted power consumption and the measured power consumption, and determining whether the motor of the flipping machine is faulty based on the comparison result.

[0009] As an embodiment of the present invention, the method for obtaining the output torque of the reducer of the left mechanism of the flipping machine based on the equipment parameters and load parameters includes: obtaining the horizontal angle of the left crank based on the angle between the left crank and the horizontal direction when the initial flipping arm is horizontal and the rotation angle of the reducer output shaft; obtaining the two-dimensional coordinates of the left crank rotation pivot point based on the horizontal angle of the left crank; obtaining the two-dimensional coordinates of the left rocker arm rotation pivot point based on the two-dimensional coordinates of the left crank rotation pivot point and the two-dimensional coordinates of the left flipping arm rotation pivot point; and obtaining the two-dimensional coordinates of the left rocker arm rotation pivot point based on the two-dimensional coordinates of the left crank rotation pivot point and the two-dimensional coordinates of the left flipping arm rotation pivot point. Using the two-dimensional coordinates of the pivot point and the two-dimensional coordinates of the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, the initial position of the left rocker arm and the horizontal direction, the angle between the left transmission rod and the horizontal direction, and the distance from the reducer output shaft to the left transmission rod are obtained. Based on the two-dimensional coordinates of the pivot point of the left crank, the two-dimensional coordinates of the pivot point of the left rocker arm, and the two-dimensional coordinates of the reducer output shaft, the torque of the load plate about the origin is obtained. Based on the mass of the load plate, the initial distance between the center of mass of the load plate and the pivot point of the left rocker arm, the angle between the center of mass of the load plate and the horizontal plane of the pivot point of the left rocker arm, and the distance between the left crank and the pivot point of the left rocker arm, the torque of the load plate about the origin is obtained. The rotational torque of the load plate on the pivot point of the left rocker arm is obtained by considering the angle between the side rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position. Based on the number of left cantilever arms, the mass of the left cantilever arms, the distance between the center of mass of the left cantilever arm and the pivot point of the left rocker arm at the initial position, the angle between the center of mass of the left cantilever arm and the horizontal plane at the initial position, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the left cantilever arm on the pivot point of the left rocker arm is obtained. Based on the mass of the left rocker arm and the distance between the center of mass of the left rocker arm and the pivot point of the left rocker arm... The rotational torque of the left rocker arm relative to the left rocker arm's pivot point is obtained by considering the angle between the left rocker arm and the horizontal direction. Based on the rotational torque of the load steel plate relative to the left rocker arm's pivot point, the rotational torque of the left cantilever relative to the left rocker arm's pivot point, the rotational torque of the left rocker arm relative to the left rocker arm's pivot point, the distance from the reducer output shaft to the left transmission rod, the mass of the left transmission rod, the distance between the center of mass of the left transmission rod and the connection point of the left rocker arm, the angle between the left transmission rod and the horizontal direction, and the angle between the left rocker arm and the horizontal direction, the output torque of the reducer of the left mechanism of the flipping machine is obtained.

[0010] As an embodiment of the present invention, the method for obtaining the output torque of the reducer of the right-side mechanism of the flipping machine based on the equipment parameters and load parameters includes: obtaining the horizontal angle of the right crank based on the angle between the right crank and the horizontal direction when the initial flipping arm is horizontal and the rotation angle of the reducer output shaft; obtaining the two-dimensional coordinates of the right crank rotation pivot point based on the right crank horizontal angle; obtaining the two-dimensional coordinates of the right rocker arm rotation pivot point based on the two-dimensional coordinates of the right crank rotation pivot point and the two-dimensional coordinates of the right flipping arm rotation pivot point; and obtaining the two-dimensional coordinates of the right rocker arm rotation pivot point based on the two-dimensional coordinates of the right crank rotation pivot point and the two-dimensional coordinates of the right flipping arm rotation pivot point. Using the two-dimensional coordinates of the pivot point and the two-dimensional coordinates of the right rocker arm pivot point, we obtain the angle between the right rocker arm and the horizontal direction, the initial angle between the right rocker arm and the horizontal direction, the angle between the right transmission rod and the horizontal direction, and the distance from the reducer output shaft to the right transmission rod. Based on the two-dimensional coordinates of the right crank pivot point, the right rocker arm pivot point, and the reducer output shaft, we obtain the torque of the load plate about the origin. Based on the mass of the load plate, the initial distance between the center of mass of the load plate and the pivot point of the right rocker arm, the angle between the center of mass of the load plate and the horizontal plane of the pivot point of the right rocker arm, and the distance from the right crank output shaft to the right transmission rod, we obtain the torque of the load plate about the origin. The rotational torque of the load plate on the right rocker's pivot point is obtained by considering the angle between the side rocker and the horizontal direction, and the angle between the right rocker and the horizontal direction at the initial position. Based on the number of right cantilever arms, the mass of the right cantilever arms, the distance between the center of mass of the right cantilever arm and the pivot point of the right rocker at the initial position, the angle between the center of mass of the right cantilever arm and the horizontal plane at the initial position, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position. The rotational torque of the right cantilever arm on the pivot point of the right rocker is also obtained based on the mass of the right rocker arm and the distance between the center of mass of the right rocker arm and the pivot point of the right rocker. The rotational torque of the right rocker arm relative to the right rocker arm's pivot point is obtained by considering the angle between the right rocker arm and the horizontal direction. Based on the rotational torque of the load steel plate relative to the right rocker arm's pivot point, the rotational torque of the right cantilever relative to the right rocker arm's pivot point, the rotational torque of the right rocker arm relative to the right rocker arm's pivot point, the distance from the reducer output shaft to the right transmission rod, the mass of the right transmission rod, the distance between the center of mass of the right transmission rod and the connection point of the right rocker arm, the angle between the right transmission rod and the horizontal direction, and the angle between the right rocker arm and the horizontal direction, the output torque of the reducer of the right mechanism of the flipping machine is obtained.

[0011] As an embodiment of the present invention, the method described above for obtaining the predicted power consumption of the flipper in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer includes: integrating the output torque of the left mechanism reducer and the output torque of the right mechanism reducer with respect to the flipping cycle to obtain the predicted power consumption of the flipper in one flipping cycle.

[0012] As an embodiment of the present invention, the method described above, which compares the predicted power consumption with the measured power consumption and determines whether the motor of the flipping machine is faulty based on the comparison result, includes: calculating the difference between the predicted power consumption and the measured power consumption; if the difference is greater than a set value, then it is determined that the motor of the flipping machine is faulty.

[0013] According to a second aspect of the present invention, a structural optimization method based on predicted power consumption of a flipping machine is provided. The method includes: acquiring equipment parameters of the flipping machine during the flipping process and load parameters of the load steel plate; obtaining the output torque of the left-side mechanism reducer and the output torque of the right-side mechanism reducer of the flipping machine based on the equipment parameters and load parameters; obtaining the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left-side mechanism reducer and the output torque of the right-side mechanism reducer; predicting the real-time power of the motor during the flipping process based on the output torque of the left-side mechanism reducer, the output torque of the right-side mechanism reducer, and the reduction ratio of the reducer; obtaining the maximum power of the motor based on the real-time power of the motor; and optimizing the structure of the flipping machine based on the predicted power consumption and the maximum power of the motor.

[0014] As an embodiment of the present invention, the method for obtaining the output torque of the reducer of the left mechanism of the flipping machine based on the equipment parameters and load parameters includes: obtaining the horizontal angle of the left crank based on the angle between the left crank and the horizontal direction when the initial flipping arm is horizontal and the rotation angle of the reducer output shaft; obtaining the two-dimensional coordinates of the left crank rotation pivot point based on the horizontal angle of the left crank; obtaining the two-dimensional coordinates of the left rocker arm rotation pivot point based on the two-dimensional coordinates of the left crank rotation pivot point and the two-dimensional coordinates of the left flipping arm rotation pivot point; and obtaining the two-dimensional coordinates of the left rocker arm rotation pivot point based on the two-dimensional coordinates of the left crank rotation pivot point and the two-dimensional coordinates of the left flipping arm rotation pivot point. Using the two-dimensional coordinates of the pivot point and the two-dimensional coordinates of the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, the initial position of the left rocker arm and the horizontal direction, the angle between the left transmission rod and the horizontal direction, and the distance from the reducer output shaft to the left transmission rod are obtained. Based on the two-dimensional coordinates of the pivot point of the left crank, the two-dimensional coordinates of the pivot point of the left rocker arm, and the two-dimensional coordinates of the reducer output shaft, the torque of the load plate about the origin is obtained. Based on the mass of the load plate, the initial distance between the center of mass of the load plate and the pivot point of the left rocker arm, the angle between the center of mass of the load plate and the horizontal plane of the pivot point of the left rocker arm, and the distance between the left crank and the pivot point of the left rocker arm, the torque of the load plate about the origin is obtained. The rotational torque of the load plate on the pivot point of the left rocker arm is obtained by considering the angle between the side rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position. Based on the number of left cantilever arms, the mass of the left cantilever arms, the distance between the center of mass of the left cantilever arm and the pivot point of the left rocker arm at the initial position, the angle between the center of mass of the left cantilever arm and the horizontal plane at the initial position, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the left cantilever arm on the pivot point of the left rocker arm is obtained. Based on the mass of the left rocker arm and the distance between the center of mass of the left rocker arm and the pivot point of the left rocker arm... The rotational torque of the left rocker arm relative to the left rocker arm's pivot point is obtained by considering the angle between the left rocker arm and the horizontal direction. Based on the rotational torque of the load steel plate relative to the left rocker arm's pivot point, the rotational torque of the left cantilever relative to the left rocker arm's pivot point, the rotational torque of the left rocker arm relative to the left rocker arm's pivot point, the distance from the reducer output shaft to the left transmission rod, the mass of the left transmission rod, the distance between the center of mass of the left transmission rod and the connection point of the left rocker arm, the angle between the left transmission rod and the horizontal direction, and the angle between the left rocker arm and the horizontal direction, the output torque of the reducer of the left mechanism of the flipping machine is obtained.

[0015] As an embodiment of the present invention, the method for obtaining the output torque of the reducer of the right-side mechanism of the flipping machine based on the equipment parameters and load parameters includes: obtaining the horizontal angle of the right crank based on the angle between the right crank and the horizontal direction when the initial flipping arm is horizontal and the rotation angle of the reducer output shaft; obtaining the two-dimensional coordinates of the right crank rotation pivot point based on the right crank horizontal angle; obtaining the two-dimensional coordinates of the right rocker arm rotation pivot point based on the two-dimensional coordinates of the right crank rotation pivot point and the two-dimensional coordinates of the right flipping arm rotation pivot point; and obtaining the two-dimensional coordinates of the right rocker arm rotation pivot point based on the two-dimensional coordinates of the right crank rotation pivot point and the two-dimensional coordinates of the right flipping arm rotation pivot point. Using the two-dimensional coordinates of the pivot point and the two-dimensional coordinates of the right rocker arm pivot point, we obtain the angle between the right rocker arm and the horizontal direction, the initial angle between the right rocker arm and the horizontal direction, the angle between the right transmission rod and the horizontal direction, and the distance from the reducer output shaft to the right transmission rod. Based on the two-dimensional coordinates of the right crank pivot point, the right rocker arm pivot point, and the reducer output shaft, we obtain the torque of the load plate about the origin. Based on the mass of the load plate, the initial distance between the center of mass of the load plate and the pivot point of the right rocker arm, the angle between the center of mass of the load plate and the horizontal plane of the pivot point of the right rocker arm, and the distance from the right crank output shaft to the right transmission rod, we obtain the torque of the load plate about the origin. The rotational torque of the load plate on the right rocker's pivot point is obtained by considering the angle between the side rocker and the horizontal direction, and the angle between the right rocker and the horizontal direction at the initial position. Based on the number of right cantilever arms, the mass of the right cantilever arms, the distance between the center of mass of the right cantilever arm and the pivot point of the right rocker at the initial position, the angle between the center of mass of the right cantilever arm and the horizontal plane at the initial position, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position. The rotational torque of the right cantilever arm on the pivot point of the right rocker is also obtained based on the mass of the right rocker arm and the distance between the center of mass of the right rocker arm and the pivot point of the right rocker. The rotational torque of the right rocker arm relative to the right rocker arm's pivot point is obtained by considering the angle between the right rocker arm and the horizontal direction. Based on the rotational torque of the load steel plate relative to the right rocker arm's pivot point, the rotational torque of the right cantilever relative to the right rocker arm's pivot point, the rotational torque of the right rocker arm relative to the right rocker arm's pivot point, the distance from the reducer output shaft to the right transmission rod, the mass of the right transmission rod, the distance between the center of mass of the right transmission rod and the connection point of the right rocker arm, the angle between the right transmission rod and the horizontal direction, and the angle between the right rocker arm and the horizontal direction, the output torque of the reducer of the right mechanism of the flipping machine is obtained.

[0016] As an embodiment of the present invention, the method described above for obtaining the predicted power consumption of the flipper in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer includes: integrating the output torque of the left mechanism reducer and the output torque of the right mechanism reducer with respect to the flipping cycle to obtain the predicted power consumption of the flipper in one flipping cycle.

[0017] As an embodiment of the present invention, the above method for optimizing the structure of the flipping machine based on the predicted power consumption and the maximum power of the motor includes: adjusting the equipment parameters and the load parameters to reduce the predicted power consumption, and selecting the motor of the flipping machine based on the maximum power of the motor.

[0018] According to a third aspect of the present invention, a fault detection device based on predicted power consumption of a flipping machine is provided. The device includes: a parameter acquisition unit for acquiring equipment parameters of the flipping machine and load parameters of the load steel plate during the flipping process; a torque acquisition unit for obtaining the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters; a power consumption prediction unit for obtaining the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer; and a fault analysis unit for comparing the predicted power consumption and the measured power consumption, and determining whether the motor of the flipping machine has a fault based on the comparison result.

[0019] According to a fourth aspect of the present invention, a structural optimization device based on predicted power consumption of a flipping machine is provided. The device includes: a parameter acquisition unit for acquiring equipment parameters of the flipping machine and load parameters of the load steel plate during the flipping process; a torque acquisition unit for obtaining the output torque of the left mechanism reducer and the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters; a power consumption prediction unit for obtaining the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer; a real-time power prediction unit for predicting the real-time power of the motor during the flipping process based on the output torque of the left mechanism reducer, the output torque of the right mechanism reducer, and the reduction ratio of the reducer; a maximum power acquisition unit for obtaining the maximum power of the motor based on the real-time power of the motor; and a structural optimization unit for optimizing the structure of the flipping machine based on the predicted power consumption and the maximum power of the motor.

[0020] According to a fifth aspect of the present invention, an electronic device is provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the above-described method.

[0021] According to a sixth aspect of the present invention, a computer-readable storage medium is provided having a computer program stored thereon, which, when executed by a processor, implements the steps of the above-described method.

[0022] According to a seventh aspect of the present invention, a computer program product is provided, comprising a computer program / instructions that, when executed by a processor, implement the steps of the above-described method.

[0023] As can be seen from the above technical solution, the fault detection and structural optimization method and device based on predicted power consumption of a flipping machine provided by this invention parameterizes all known quantities of the flipping machine. By calculating the motion of the crank rocker arm and considering the torque changes of the two flipping arms, the torque during the flipping process is obtained. Then, the work done during the flipping cycle can be calculated by integrating the torque with respect to the flipping cycle, thereby obtaining the power consumption data during the flipping process. By utilizing this power consumption data, this application can achieve real-time monitoring of the operating status of the flipping machine and early warning of faults. By comparing the deviation between the actual power consumption and the theoretical power consumption, it can accurately determine whether there are abnormalities such as mechanical wear, decreased transmission efficiency, or changes in structural parameters. At the same time, based on the power consumption data and motor power prediction data, this application can establish the optimal combination of structural parameters for different steel plate specifications, providing a reference for the selection of flipping machine motors, significantly reducing energy consumption and saving production costs. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings:

[0025] Figure 1 This is a structural schematic diagram of a flipping machine provided in this application;

[0026] Figure 2 This is a simplified schematic diagram of the left and right mechanisms of the output shaft of the flip-board machine reducer provided in this application;

[0027] Figure 3 This is a flowchart illustrating a fault detection method based on predicted power consumption of a flip-board machine, provided in an embodiment of this application.

[0028] Figure 4 This is a schematic diagram of the process for obtaining the output torque of the reducer of the left-side mechanism, provided in an embodiment of this application.

[0029] Figure 5 This is a schematic diagram of the process for obtaining the output torque of the reducer of the right-side mechanism according to an embodiment of this application;

[0030] Figure 6 This is a schematic flowchart of a structural optimization method based on predicting power consumption of a flip-board machine, provided in an embodiment of this application.

[0031] Figure 7 This is a schematic diagram of a fault detection device based on the predicted power consumption of a flip-board machine, provided in an embodiment of this application.

[0032] Figure 8 This is a schematic diagram of a structural optimization device based on predicting power consumption of a flip-board machine, provided in an embodiment of this application.

[0033] Figure 9 This is a schematic diagram of the electronic device provided in the embodiments of this application. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Here, the illustrative embodiments of the present invention and their descriptions are used to explain the present invention, but are not intended to limit the present invention.

[0035] like Figure 1 The diagram shows a structural schematic of a steel plate flipping machine provided in this application. It uses two sets of crank-rocker mechanisms to flip the steel plates, thereby turning them over. The main drive motor of the flipping machine is connected to the corresponding crank via a reducer output shaft. The cranks on both sides are connected to the rocker on the other side via a transmission rod. The other side of the rocker is interference-fitted to the main drive shaft, and one side of the flipping arm is also interference-fitted to the main drive shaft. The number of flipping arms can be determined according to the length of the steel plate. Generally, the spacing between the flipping arms is about 2 meters. One set of flipping arms is driven by a motor reducer. Due to the phase difference between the two flipping arms, the steel plate can be flipped.

[0036] like Figure 2 As shown Figure 1 A simplified schematic diagram of the left and right mechanisms of the reducer output shaft of the medium-sized flip-plate machine, showing that both the left and right mechanisms can be... Figure 2 To simplify the illustration. (By...) Figure 2 As can be seen, the origin (point O) is first set at the location of the reducer output shaft, point P is the crank rotation pivot point, point Q is the rocker arm rotation pivot point, and point R is the tilting arm rotation pivot point. Let the coordinate of R be (x... R ,y R The crank length is l1, the transmission rod length is l2, the rocker arm length is l3, and the angle between the crank and the horizontal direction when the boom is horizontal is α0 (radians). The independent variable is the crank rotation angle β (radians), and the dependent variable is the rocker arm rotation angle γ.

[0037] like Figure 3 The diagram shown is a flowchart illustrating a fault detection method based on predicted power consumption of a flip-board machine according to an embodiment of this application. The method includes the following steps:

[0038] Step S301: Obtain the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process.

[0039] In this embodiment, equipment parameters refer to performance parameters, structural parameters, geometric parameters, etc., related to the mechanical structure of the flipping machine, while load parameters refer to some parameters related to the load steel plate.

[0040] Preferably, the equipment parameters in this step may include: reducer reduction ratio, motor rotation angle when the steel plate moves from the left tilting arm to the right tilting arm, reducer output speed, reducer output horizontal coordinate, reducer output vertical coordinate, left crank length, left transmission rod length, left rocker length, angle between the left crank and the horizontal direction when the tilting arm is initially horizontal, horizontal coordinate of the left tilting arm rotation pivot point, vertical coordinate of the left tilting arm rotation pivot point, left cantilever mass, number of left cantilever arms, left rocker mass, left transmission rod mass, left crank mass, distance between the center of mass of the left cantilever and the pivot point of the left rocker at the initial position, distance between the center of mass of the left rocker and the pivot point of the left rocker, distance between the center of mass of the left transmission rod and the connection point of the left rocker, distance between the center of mass of the left crank and the motor output shaft, and angle between the initial center of mass of the left cantilever and the horizontal plane of the pivot point of the left rocker.

[0041] Preferably, the load parameters of the load steel plate in this step may include: the mass of the load steel plate, the initial distance between the center of gravity of the load steel plate and the pivot point of the left rocker arm, and the angle between the center of gravity of the load steel plate and the horizontal plane of the pivot point of the left rocker arm.

[0042] Step S302: Based on the equipment parameters and load parameters, obtain the output torque of the left mechanism reducer and the right mechanism reducer of the flipping machine.

[0043] In this step, the output torque of the left mechanism reducer and the output torque of the right mechanism reducer during the flipping process can be obtained by calculating the motion of the crank rocker and taking into account the torque changes of the two flipping arms.

[0044] Step S303: Obtain the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer.

[0045] Step S304: Compare the predicted power consumption with the measured power consumption, and determine whether the motor of the flipping machine is faulty based on the comparison result.

[0046] In this step, the difference between the predicted power consumption and the measured power consumption can be calculated. If the difference is greater than a set value, it is determined that the motor of the flipper is faulty. For example, if the measured power consumption is significantly higher than the predicted power consumption, it may be due to motor performance degradation or additional energy consumption in the transmission device, such as bearing friction or component aging. If the measured power consumption is lower than the predicted value, it indicates that there may be anomalies in the equipment sensor data. This comparison method can not only detect whether the flipper is operating normally, but also provide guidance for energy-saving design.

[0047] Preferred, such as Figure 4 As shown, the step S302 above, which obtains the output torque of the left-side mechanism reducer of the flipping machine based on the equipment parameters and load parameters, includes the following sub-steps:

[0048] Step S401: Obtain the horizontal angle of the left crank based on the angle between the left crank and the horizontal direction when the initial tilting arm is horizontal and the rotation angle of the reducer output shaft.

[0049] The horizontal angle of the left crank can be obtained in this step using the following formula (1):

[0050] α 1L =α 0L +β (1)

[0051] Where, α 0L α is the angle between the left crank and the horizontal direction when the boom is initially horizontal, in rad; 1L β is the horizontal angle of the left crank, in rad; β is the rotation angle of the reducer output shaft, which is the same as the crank rotation angle mentioned above, and can be obtained by the following formulas (2) and (3):

[0052]

[0053] β=ωt (3)

[0054] Where ω is the angular velocity of the reducer output shaft (rad / s); n is the output speed of the reducer output shaft (r / min); and t is time (s).

[0055] Step S402: Obtain the two-dimensional coordinates of the left crank rotation pivot point based on the horizontal angle of the left crank.

[0056] That is, the two-dimensional coordinates of the left crank pivot point are obtained by the following equations (4) and (5):

[0057] x PL =l 1L cosα 1L (4)

[0058] y PL =l 1L sinα 1L (5)

[0059] Where x PL The x-coordinate of the crank pivot point on the left side is in mm; y PL The vertical coordinate of the crank pivot point on the left side is in mm.

[0060] Step S403: Based on the two-dimensional coordinates of the left crank rotation pivot point and the two-dimensional coordinates of the left flap arm rotation pivot point, obtain the two-dimensional coordinates of the left rocker arm rotation pivot point.

[0061] In this step, we first assume:

[0062] a L =2(x PL -x PL (6)

[0063] b L =2(y PL -y RL (7)

[0064] c L =l 3L 2 -l 2L 2 -(x PL 2 -x RL 2 )-(y PL 2 -y RL 2 (8)

[0065]

[0066]

[0067]

[0068] Then we can obtain the two-dimensional coordinates of the pivot point of the left joystick:

[0069]

[0070]

[0071] Where x QL The x-coordinate of the left joystick's rotation pivot point is in mm; y QL The vertical coordinate of the pivot point of the left joystick is in mm.

[0072] Step S404: Based on the two-dimensional coordinates of the left crank rotation pivot point, the left tilting arm rotation pivot point, and the left rocker rotation pivot point, obtain the angle between the left rocker and the horizontal direction, the angle between the left rocker and the horizontal direction at the initial position, the angle between the left transmission rod and the horizontal direction, and the distance from the reducer output shaft to the left transmission rod.

[0073] Specifically, the angle between the left rocker arm and the horizontal direction, the angle between the left rocker arm and the horizontal direction at the initial position, the angle between the left transmission rod and the horizontal direction, and the distance from the reducer output shaft to the left transmission rod are obtained through the following formulas (14), (15), (16), and (17):

[0074]

[0075]

[0076]

[0077]

[0078] Where, α 3L α is the angle between the left joystick and the horizontal direction, in rad; 3L0 The angle between the left joystick and the horizontal direction at the initial position is rad; α 2L The angle between the left drive rod and the horizontal direction is rad; l RL-l2L The distance from the reducer output shaft to the left drive rod is in mm; l 2L The length of the left drive rod is in mm; l 3L The length of the left joystick is in mm.

[0079] Step S405: Based on the two-dimensional coordinates of the left crank rotation pivot point, the two-dimensional coordinates of the left rocker rotation pivot point, and the two-dimensional coordinates of the reducer output shaft, the torque of the load steel plate on the origin is obtained.

[0080] Specifically, the torque of the load plate about the origin is obtained through the following formula (18):

[0081]

[0082] In the above formula, l O-l2L The torque of the load plate about the origin is expressed in mm; x O y is the x-coordinate of the reducer output shaft, in mm; O The vertical coordinate of the reducer output shaft, in mm.

[0083] Step S406: Based on the mass of the load steel plate, the initial distance between the center of mass of the load steel plate and the pivot point of the left rocker arm, the horizontal angle between the center of mass of the load steel plate and the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the load steel plate on the pivot point of the left rocker arm is obtained.

[0084] In this step, the rotational torque of the load steel plate on the left rocker arm hinge point varies depending on the rotation angle of the reducer output shaft. Specifically:

[0085] when hour,

[0086]

[0087] when hour,

[0088] M RL-g =0 (20)

[0089] in, The crank rotation angle is expressed in rad; M RL-g The rotational torque of the load steel plate on the hinge point of the left rocker arm is expressed in N·m.

[0090] Step S407: Based on the number of left cantilever arms, the mass of the left cantilever arms, the distance between the center of mass of the left cantilever arms and the pivot point of the left rocker arm at the initial position, the horizontal angle between the center of mass of the left cantilever arms and the pivot point of the left rocker arm at the initial position, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the left cantilever arms on the pivot point of the left rocker arm is obtained.

[0091] Specifically, the rotational torque of the left cantilever on the left rocker arm's pivot point is obtained according to the following formula (21):

[0092]

[0093] Among them, M RL-l4L The rotational torque of the left cantilever relative to the pivot point of the left rocker arm is expressed in N·m. l4L Number of left-side cantilever arms, in units; m l4L The mass of the left cantilever is kg; g is the acceleration due to gravity, N / kg; l l4L-RL α is the distance between the center of mass of the left cantilever and the pivot point of the left rocker arm at the initial position, in mm; l4L-RL Let be the angle between the initial center of mass of the left cantilever and the horizontal plane of the pivot point of the left rocker arm, in rad.

[0094] Step S408: Based on the mass of the left joystick, the distance between the center of mass of the left joystick and the pivot point of the left joystick, and the angle between the left joystick and the horizontal direction, obtain the rotational torque of the left joystick on the pivot point of the left joystick.

[0095] Specifically, the rotational torque of the left joystick relative to the pivot point of the left joystick is obtained according to the following formula (22):

[0096]

[0097] Among them, M RL-l3L The rotational torque of the left joystick relative to its pivot point is expressed in N·m. l3L The mass of the left joystick is kg; g is the acceleration due to gravity, N / kg; l l3L-RL This is the distance in mm from the center of mass of the left joystick to the pivot point of the left joystick.

[0098] Step S409: Based on the rotational torque of the load steel plate on the left rocker arm's rotational pivot point, the rotational torque of the left cantilever on the left rocker arm's rotational pivot point, the rotational torque of the left rocker arm on the left rocker arm's rotational pivot point, the distance from the reducer output shaft to the left transmission rod, the mass of the left transmission rod, the distance between the center of mass of the left transmission rod and the connection point of the left rocker arm, the angle between the left transmission rod and the horizontal direction, and the angle between the left rocker arm and the horizontal direction, the output torque of the reducer of the left mechanism of the flipping machine is obtained.

[0099] Specifically, this step can be achieved by sequentially obtaining the output torque of the reducer of the left mechanism of the flipper using the following formulas (23)-(27):

[0100]

[0101]

[0102] N 21LY =m l2L gG 32L sinα 3L -P 23L sinα 2L (25)

[0103] N 21LX =G 32L cosα 3L -P 23L cosα 2L (26)

[0104]

[0105] Among them, P 23L The left joystick applies a driving force, N; G, to the left drive lever. 32L The force exerted on the left joystick by the weight of the left transmission rod (the pulling force of the joystick), N; N 21LY The force exerted by the left joystick on the left crank (in the direction of gravity), N; N 21LX The force exerted by the left joystick on the left crank (horizontal direction), N; M L The torque is the output torque of the reducer on the left side of the flipper, in N·m.

[0106] Preferred, such as Figure 5 As shown, in step S302 above, obtaining the output torque of the right-side mechanism reducer of the flipping machine based on the equipment parameters and load parameters includes:

[0107] Step S501: Obtain the horizontal angle of the right crank based on the angle between the right crank and the horizontal direction when the initial tilting arm is horizontal and the rotation angle of the reducer output shaft.

[0108] The horizontal angle of the left crank can be obtained in this step using the following formula (28):

[0109] α 1R =α 0R +β (28)

[0110] Where, α 0R α is the angle between the right crank and the horizontal direction when the boom is initially horizontal, in rad; 1R α is the horizontal angle of the right crank, in rad; β is the rotation angle of the reducer output shaft.

[0111] Step S502: Obtain the two-dimensional coordinates of the right crank rotation pivot point based on the horizontal angle of the right crank.

[0112] That is, the two-dimensional coordinates of the left crank pivot point are obtained by the following equations (29) and (30):

[0113] x PR =l 1R cosα 1R (29)

[0114] y PR =l 1R sinα 1R (30)

[0115] Where x PR The x-coordinate of the right crank's pivot point is in mm; y PR The vertical coordinate of the right crank's pivot point is in mm.

[0116] Step S503: Based on the two-dimensional coordinates of the right crank rotation pivot point and the right flap arm rotation pivot point, obtain the two-dimensional coordinates of the right rocker arm rotation pivot point.

[0117] In this step, we first assume:

[0118] a R =2(x PR -x RR (31)

[0119] b R =2(y PR -y RR (32)

[0120] c R =l 3R 2 -l 2R 2 -(x PR 2 -x RR 2 )-(y PR2 -y RR 2 (33)

[0121]

[0122]

[0123]

[0124] Then we can obtain the two-dimensional coordinates of the right joystick's rotation pivot point:

[0125]

[0126]

[0127] Where x QR The x-coordinate of the right joystick's rotation pivot point is in mm; y QR The vertical coordinate of the right joystick's rotation point is in mm.

[0128] Step S504: Based on the two-dimensional coordinates of the right crank rotation pivot point, the right tilting arm rotation pivot point, and the right rocker rotation pivot point, obtain the angle between the right rocker and the horizontal direction, the angle between the right rocker and the horizontal direction at the initial position, the angle between the right transmission rod and the horizontal direction, and the distance from the reducer output shaft to the right transmission rod.

[0129] Specifically, the angles between the right and left rockers and the horizontal direction, the angles between the right rocker and the horizontal direction at the initial position, the angles between the right transmission rod and the horizontal direction, and the distance from the reducer output shaft to the right transmission rod are obtained through the following formulas (39)-(42):

[0130]

[0131]

[0132]

[0133]

[0134] Where, α 3R α is the angle between the right joystick and the horizontal direction, in rad; 3R0 The angle between the right joystick and the horizontal direction at the initial position is rad; α 2R The angle between the right drive rod and the horizontal direction is rad; l RR-l2R The distance from the reducer output shaft to the right drive rod is in mm; l 2R The length of the right-side drive rod is in mm; l 3R The length of the right joystick is in mm.

[0135] Step S505: Based on the two-dimensional coordinates of the right crank rotation pivot point, the two-dimensional coordinates of the right rocker rotation pivot point, and the two-dimensional coordinates of the reducer output shaft, the torque of the load steel plate on the origin is obtained.

[0136] Specifically, the torque of the load steel plate on the rotating hinge point () is obtained through the following formula (43):

[0137]

[0138] Among them, l O-l2R The torque of the load plate about the origin is expressed in mm; x O y is the x-coordinate of the reducer output shaft, in mm; O The vertical coordinate of the reducer output shaft, in mm.

[0139] Step S506: Based on the mass of the load steel plate, the initial distance between the center of mass of the load steel plate and the pivot point of the right rocker arm, the horizontal angle between the center of mass of the load steel plate and the pivot point of the right rocker arm, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position, the rotational torque of the load steel plate on the pivot point of the right rocker arm is obtained.

[0140] In this step, the rotational torque of the load steel plate on the left rocker arm hinge point varies depending on the rotation angle of the reducer output shaft. Specifically:

[0141] when hour,

[0142] M RR-g =0 (44)

[0143] when hour,

[0144]

[0145] in, The crank rotation angle is expressed in rad; M RR-g The rotational torque of the load steel plate on the right rocker arm hinge point is expressed in N·m.

[0146] Step S507: Based on the number of right cantilever arms, the mass of the right cantilever arms, the distance between the center of mass of the right cantilever arms and the pivot point of the right rocker arm at the initial position, the horizontal angle between the initial center of mass of the right cantilever arms and the pivot point of the right rocker arm, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position, the rotational torque of the right cantilever arms on the pivot point of the right rocker arm is obtained.

[0147] Specifically, the rotational torque of the right cantilever on the right rocker arm's pivot point is obtained according to the following formula (46):

[0148]

[0149] Among them, M RR-l4R The rotational torque of the right cantilever on the right rocker arm's pivot point, in N·m; l4R The number of right-side cantilever arms is in units; m l4R The mass of the right cantilever is kg; g is the acceleration due to gravity, N / kg; l l4R-RR The distance between the center of mass of the right cantilever and the pivot point of the right rocker arm at the initial position, in mm; α l4R-RR Let be the angle between the initial center of mass of the right cantilever and the horizontal plane of the pivot point of the right rocker arm, in rad.

[0150] Step S508: Based on the mass of the right rocker arm, the distance between the center of mass of the right rocker arm and the pivot point of the right rocker arm, and the angle between the right rocker arm and the horizontal direction, obtain the rotational torque of the right rocker arm on the pivot point of the right rocker arm.

[0151] Specifically, the rotational torque of the right joystick relative to the right joystick pivot point is obtained according to the following formula (47):

[0152]

[0153] Among them, M RR-l3R The rotational torque of the right joystick relative to its pivot point is expressed in N·m. l3R The mass of the right joystick is kg; g is the acceleration due to gravity, N / kg; l l3R-RR This is the distance in mm from the center of mass of the right rocker arm to the pivot point of the right rocker arm.

[0154] Step S509: Based on the rotational torque of the load steel plate on the right rocker arm's rotational pivot point, the rotational torque of the right cantilever on the right rocker arm's rotational pivot point, the rotational torque of the right rocker arm on the right rocker arm's rotational pivot point, the distance from the reducer output shaft to the right transmission rod, the mass of the right transmission rod, the distance between the center of mass of the right transmission rod and the connection point of the right rocker arm, the angle between the right transmission rod and the horizontal direction, and the angle between the right rocker arm and the horizontal direction, the output torque of the reducer of the right mechanism of the flipping machine is obtained.

[0155] Specifically, this step can be achieved by sequentially obtaining the output torque of the reducer of the right-side mechanism of the flipper using the following formulas (48)-(52):

[0156]

[0157]

[0158] N 21RY =m l2R gG 32R sin(π-α3R )-P 23R sinα 2R (50)

[0159] N 21RX =G 32R cos(π-α 3R )-P 23R cosα 2R (51)

[0160]

[0161] Among them, P 23R The right joystick applies a driving force, N; G, to the right drive lever. 32R The force exerted on the right joystick by the weight of the right transmission rod (the pulling force of the joystick), N; N 21RY The force exerted by the right joystick on the right crank (in the direction of gravity), N; N 21RX The force exerted by the right rocker arm on the right crank (horizontal direction), N; M R The torque is the output torque of the reducer on the right side of the flipper, in N·m.

[0162] As can be seen, through the above steps S401-S409 and S501-S509, this application can obtain the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters.

[0163] More preferably, in step S303 above, obtaining the predicted power consumption of the flipper in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer further includes: integrating the output torque of the left mechanism reducer and the output torque of the right mechanism reducer over the flipping cycle to obtain the predicted power consumption of the flipper in one flipping cycle.

[0164] The motor drives the cranks on both sides to rotate through the output shaft of the reducer. The cranks on both sides drive their respective swing arms to rotate through the transmission rod. The swing arms on both sides drive the flipping arms on both sides to complete the flipping of the steel plate through the action of the hinge point R. During the flipping process, the total motor torque is M. After obtaining the output torque of the reducer of the left mechanism and the reducer of the right mechanism of the flipping machine, the total motor torque M can be obtained by the following formula (53):

[0165]

[0166] Where M is the total output torque of the motor, N·m; and I is the reduction ratio of the reducer.

[0167] Then, the predicted power consumption of the flipping machine during one flipping cycle can be calculated by the following formula (54):

[0168]

[0169] Where Q is the total power consumption in one cycle, in kW·h.

[0170] As described above, the fault detection method based on predicted power consumption of a flip-board machine provided in this application parameterizes all known quantities of the flip-board machine. By calculating the motion of the crank and rocker arm, and considering the torque changes of the two flipping arms, the torque during the flipping process is obtained. Then, the work done during the flipping cycle can be calculated by integrating the torque over the flipping cycle, thus obtaining the power consumption data during the flipping process. By utilizing this power consumption data, this application can achieve real-time monitoring of the flip-board machine's operating status and early warning of faults. By comparing the deviation between actual power consumption and theoretical power consumption, it can accurately determine whether the equipment has abnormal conditions such as mechanical wear, decreased transmission efficiency, or changes in structural parameters.

[0171] like Figure 6 The diagram shown is a flowchart illustrating a structural optimization method based on predicting power consumption of a flip-board machine, according to an embodiment of this application. The method includes the following steps:

[0172] Step S601: Obtain the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process.

[0173] Step S602: Based on the equipment parameters and load parameters, obtain the output torque of the left mechanism reducer and the right mechanism reducer of the flipping machine.

[0174] Step S603: Obtain the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer.

[0175] In this embodiment, steps S601-S603 can be referred to the foregoing. Figures 3-5 The corresponding descriptions in the embodiments will not be repeated here.

[0176] Step S604: Based on the output torque of the left mechanism reducer, the output torque of the right mechanism reducer, and the reduction ratio of the reducers, predict the real-time power of the motor during the flipping process.

[0177] Specifically, this step can predict the real-time power of the motor during the flipping process based on the following formula (55):

[0178]

[0179] Where P is the real-time power of the motor during the flipping process, in kW; M is the total output torque of the motor, in N·m; and n is the output speed of the reducer, in r / min.

[0180] Step S605: Obtain the maximum power of the motor based on the real-time power of the motor.

[0181] This step involves analyzing all the real-time power P of the motors obtained in step S604 above, finding the peak value, and taking it as the maximum power of the motor.

[0182] Step S606: Optimize the structure of the flipping machine based on the predicted power consumption and the maximum power of the motor.

[0183] Preferably, the optimization in this step may further include: adjusting the equipment parameters and the load parameters to reduce the predicted power consumption, and selecting the motor of the flipping machine based on the maximum power of the motor. By comprehensively adjusting equipment parameters (such as crank length, transmission rod geometry, etc.), load parameters (steel plate mass distribution), and motor selection (optimizing reduction ratio, motor model), motor power consumption can be effectively reduced, providing reliable technical support for the energy-saving design and improved operating efficiency of the flipping machine.

[0184] As described above, the structural optimization method for predicting power consumption of a flipping machine provided in this application parameterizes all known quantities of the flipping machine. By calculating the motion of the crank and rocker arm, and considering the torque changes of the two flipping arms, the torque during the flipping process is obtained. Then, the work done during the flipping cycle can be calculated by integrating the torque over the flipping cycle, thus obtaining power consumption data and motor power prediction data during the flipping process. Furthermore, based on the power consumption data and motor power prediction data, this application can establish optimal structural parameter combinations for different steel plate specifications, providing a reference for motor selection in the flipping machine, significantly reducing energy consumption and saving production costs.

[0185] The following is a specific embodiment. In this embodiment, the specific input parameters (equipment parameters and load parameters) are shown in Table 1. Using the above method, the power consumption of this steel plate during the flipping process can be calculated to be 0.76 kW·h, and the maximum power of the main motor is 156 kW. This provides a calculation method for accurately measuring the power consumption of the flipping machine in one year, and also provides a calculation basis for selecting the power of the main motor. If the actual measured power consumption of the flipping machine deviates significantly from the theoretical calculated value, the occurrence of a fault in the main motor of the flipping machine can be predicted. At the same time, changing the relevant model parameters of the flipping machine (i.e., the relevant parameters in Table 1) will affect the prediction results, which can provide technical support for energy-saving optimization design in the flipping process.

[0186] Table 1

[0187]

[0188]

[0189]

[0190] like Figure 7 The diagram shows a structural schematic of a fault detection device based on predicted power consumption of a flip-board machine according to an embodiment of this application. The device includes: a parameter acquisition unit 710, a torque acquisition unit 720, a power consumption prediction unit 730, and a fault analysis unit 740, which are connected sequentially.

[0191] The parameter acquisition unit 710 is used to acquire the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process.

[0192] The torque acquisition unit 720 is used to obtain the output torque of the left mechanism reducer and the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters.

[0193] The power consumption prediction unit 730 is used to obtain the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer.

[0194] The fault analysis unit 740 is used to compare the predicted power consumption and the measured power consumption, and to determine whether the motor of the flipping machine has a fault based on the comparison result.

[0195] For a detailed description of each of the above units, please refer to the corresponding descriptions in the foregoing method embodiments, which will not be repeated here.

[0196] As described above, the fault detection device based on predicted power consumption of a flip-board machine provided in this application parameterizes all known quantities of the flip-board machine. By calculating the motion of the crank and rocker arm, and considering the torque changes of the two flipping arms, the torque during the flipping process is obtained. Then, the work done during the flipping cycle can be calculated by integrating the torque over the flipping cycle, thus obtaining the power consumption data during the flipping process. By utilizing this power consumption data, this application can achieve real-time monitoring of the flip-board machine's operating status and early warning of faults. By comparing the deviation between actual power consumption and theoretical power consumption, it can accurately determine whether the equipment has abnormal conditions such as mechanical wear, decreased transmission efficiency, or changes in structural parameters.

[0197] like Figure 8 The diagram shown is a structural optimization device based on predicting power consumption of a flip-board machine according to an embodiment of this application. The device includes: a parameter acquisition unit 710, a torque acquisition unit 720, a power consumption prediction unit 730, a real-time power prediction unit 750, a maximum power acquisition unit 760, and a structural optimization unit 770, which are connected sequentially.

[0198] The parameter acquisition unit 710 acquires the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process.

[0199] The torque acquisition unit 720 obtains the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters.

[0200] The power consumption prediction unit 730 obtains the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer.

[0201] The real-time power prediction unit 750 predicts the real-time power of the motor during the flipping process based on the output torque of the reducer of the left mechanism, the output torque of the reducer of the right mechanism, and the reduction ratio of the reducer.

[0202] The maximum power acquisition unit 760 is used to obtain the maximum power of the motor based on the real-time power of the motor.

[0203] The structure optimization unit 770 is used to optimize the structure of the flipping machine based on the predicted power consumption and the maximum power of the motor.

[0204] For a detailed description of each of the above units, please refer to the corresponding descriptions in the foregoing method embodiments, which will not be repeated here.

[0205] As described above, the structural optimization device based on predicted power consumption of a flipping machine provided in this application parameterizes all known quantities of the flipping machine. By calculating the motion of the crank and rocker arm, and considering the torque changes of the two flipping arms, the torque during the flipping process is obtained. Then, the work done during the flipping cycle can be calculated by integrating the torque over the flipping cycle, thus obtaining power consumption data and motor power prediction data during the flipping process. Furthermore, based on the power consumption data and motor power prediction data, this application can establish optimal structural parameter combinations for different steel plate specifications, providing a reference for motor selection in the flipping machine, significantly reducing energy consumption and saving production costs.

[0206] Figure 9 This is a schematic diagram of an electronic device provided in an embodiment of the present invention. Figure 9 The illustrated electronic device is a general-purpose data processing device, comprising a general-purpose computer hardware structure, including at least a processor 801 and a memory 802. The processor 801 and memory 802 are connected via a bus 803. The memory 802 is adapted to store one or more instructions or programs executable by the processor 801. These instructions or programs are executed by the processor 801 to implement the steps in the aforementioned fault detection and structural optimization method based on predicted power consumption of a flip-board machine.

[0207] The processor 801 described above can be a standalone microprocessor or a collection of one or more microprocessors. Thus, the processor 801 executes commands stored in the memory 802, thereby performing the method flow of the embodiments of the present invention as described above to process data and control other devices. The bus 803 connects the aforementioned components together, and also connects these components to the display controller 804, the display device, and the input / output (I / O) device 805. The input / output (I / O) device 805 can be a mouse, keyboard, modem, network interface, touch input device, motion-sensing input device, printer, and other devices known in the art. Typically, the input / output (I / O) device 805 is connected to the system via an input / output (I / O) controller 806.

[0208] The memory 802 can store software components, such as an operating system, a communication module, an interaction module, and application programs. Each of the modules and application programs described above corresponds to a set of executable program instructions that perform one or more functions and the methods described in the embodiments of the invention.

[0209] This invention also provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the steps of the above-described fault detection and structural optimization method based on predicted power consumption of a flip-board machine.

[0210] This invention also provides a computer program product, including a computer program / instruction, which, when executed by a processor, implements the steps of the above-described fault detection and structural optimization method based on predicted power consumption of flip-board machines.

[0211] Preferred embodiments of the invention have been described above with reference to the accompanying drawings. Many features and advantages of these embodiments are apparent from this detailed description, and therefore the claims are intended to cover all such features and advantages of these embodiments that fall within their true spirit and scope. Furthermore, since many modifications and alterations will readily occur to those skilled in the art, the embodiments of the invention are not intended to be limited to the precise structures and operations illustrated and described, but rather to encompass all suitable modifications and equivalents falling within their scope.

[0212] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0213] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0214] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0215] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0216] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A fault detection method based on predicted power consumption of a flip-board machine, characterized in that, The method includes: Obtain the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process; Based on the equipment parameters and load parameters, the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine are obtained; The predicted power consumption of the flipper in one flipping cycle is obtained based on the output torque of the reducer of the left mechanism and the output torque of the reducer of the right mechanism. Compare the predicted power consumption with the actual power consumption, and determine whether the motor of the flipping machine is faulty based on the comparison results.

2. The fault detection method based on predicted power consumption of a flip-board machine as described in claim 1, characterized in that, The output torque of the left-side mechanism reducer of the flipping machine, obtained based on the aforementioned equipment parameters and load parameters, includes: The horizontal angle of the left crank is obtained based on the angle between the left crank and the horizontal direction when the initial boom is horizontal and the rotation angle of the reducer output shaft. The two-dimensional coordinates of the left crank pivot point are obtained based on the horizontal angle of the left crank. The two-dimensional coordinates of the left rocker arm rotation hinge point are obtained based on the two-dimensional coordinates of the left crank rotation hinge point and the left flap arm rotation hinge point. Based on the two-dimensional coordinates of the left crank rotation pivot point, the left tilting arm rotation pivot point, and the left rocker rotation pivot point, the angle between the left rocker and the horizontal direction, the angle between the left rocker and the horizontal direction at the initial position, the angle between the left transmission rod and the horizontal direction, and the distance from the reducer output shaft to the left transmission rod are obtained. Based on the two-dimensional coordinates of the left crank rotation pivot point, the two-dimensional coordinates of the left rocker rotation pivot point, and the two-dimensional coordinates of the reducer output shaft, the torque of the load steel plate on the origin is obtained. Based on the mass of the load steel plate, the initial distance between the center of mass of the load steel plate and the pivot point of the left rocker arm, the horizontal angle between the center of mass of the load steel plate and the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the load steel plate on the pivot point of the left rocker arm is obtained. Based on the number of left cantilever arms, the mass of the left cantilever arms, the distance between the center of mass of the left cantilever arms and the pivot point of the left rocker arm at the initial position, the horizontal angle between the initial center of mass of the left cantilever arms and the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the left cantilever arms on the pivot point of the left rocker arm is obtained. Based on the mass of the left joystick, the distance between the center of mass of the left joystick and the pivot point of the left joystick, and the angle between the left joystick and the horizontal direction, the rotational torque of the left joystick about the pivot point of the left joystick is obtained. Based on the rotational torque of the load steel plate on the left rocker arm's pivot point, the rotational torque of the left cantilever on the left rocker arm's pivot point, the rotational torque of the left rocker arm on the left rocker arm's pivot point, the distance from the reducer output shaft to the left transmission rod, the mass of the left transmission rod, the distance between the center of mass of the left transmission rod and the connection point of the left rocker arm, the angle between the left transmission rod and the horizontal direction, and the angle between the left rocker arm and the horizontal direction, the output torque of the reducer of the left mechanism of the flipping machine is obtained.

3. The fault detection method based on predicted power consumption of a flip-board machine as described in claim 1, characterized in that, The output torque of the right-side mechanism reducer of the flipping machine, obtained based on the aforementioned equipment parameters and load parameters, includes: The horizontal angle of the right crank is obtained based on the angle between the right crank and the horizontal direction when the initial boom is horizontal and the rotation angle of the reducer output shaft. The two-dimensional coordinates of the right crank pivot point are obtained based on the horizontal angle of the right crank. The two-dimensional coordinates of the right rocker arm rotation hinge point are obtained based on the two-dimensional coordinates of the right crank rotation hinge point and the right flap arm rotation hinge point. Based on the two-dimensional coordinates of the right crank rotation pivot point, the right tilting arm rotation pivot point, and the right rocker rotation pivot point, the angle between the right rocker and the horizontal direction, the angle between the right rocker and the horizontal direction at the initial position, the angle between the right transmission rod and the horizontal direction, and the distance from the reducer output shaft to the right transmission rod are obtained. Based on the two-dimensional coordinates of the right crank pivot point, the two-dimensional coordinates of the right rocker pivot point, and the two-dimensional coordinates of the reducer output shaft, the torque of the load steel plate on the origin is obtained. Based on the mass of the load steel plate, the initial distance between the center of mass of the load steel plate and the pivot point of the right rocker arm, the horizontal angle between the center of mass of the load steel plate and the pivot point of the right rocker arm, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position, the rotational torque of the load steel plate on the pivot point of the right rocker arm is obtained. Based on the number of right cantilever arms, the mass of the right cantilever arms, the distance between the center of mass of the right cantilever arms and the pivot point of the right rocker arm at the initial position, the horizontal angle between the initial center of mass of the right cantilever arms and the pivot point of the right rocker arm, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position, the rotational torque of the right cantilever arms on the pivot point of the right rocker arm is obtained. Based on the mass of the right rocker, the distance between the center of mass of the right rocker and the pivot point of the right rocker, and the angle between the right rocker and the horizontal direction, the rotational torque of the right rocker about the pivot point of the right rocker is obtained. Based on the rotational torque of the load steel plate on the right rocker arm's rotational pivot point, the rotational torque of the right cantilever on the right rocker arm's rotational pivot point, the rotational torque of the right rocker arm on the right rocker arm's rotational pivot point, the distance from the reducer output shaft to the right transmission rod, the mass of the right transmission rod, the distance between the center of mass of the right transmission rod and the connection point of the right rocker arm, the angle between the right transmission rod and the horizontal direction, and the angle between the right rocker arm and the horizontal direction, the output torque of the reducer of the right mechanism of the flipping machine is obtained.

4. The fault detection method based on predicted power consumption of a flip-board machine as described in claim 1, characterized in that, The method of obtaining the predicted power consumption of the tilting machine in one tilting cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer includes: The predicted power consumption of the flipping machine in one flipping cycle is obtained by integrating the output torque of the reducer of the left mechanism and the output torque of the reducer of the right mechanism over the flipping cycle.

5. The fault detection method based on predicted power consumption of a flip-board machine as described in claim 1, characterized in that, The process of comparing the predicted power consumption with the measured power consumption and determining whether the motor of the flipping machine is faulty based on the comparison result includes: Calculate the difference between the predicted power consumption and the actual power consumption. If the difference is greater than a set value, it is determined that the motor of the flipping machine is faulty.

6. A structural optimization method based on predicted power consumption of a flip-board machine, characterized in that, The method includes: Obtain the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process; Based on the equipment parameters and load parameters, the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine are obtained; The predicted power consumption of the flipper in one flipping cycle is obtained based on the output torque of the reducer of the left mechanism and the output torque of the reducer of the right mechanism. Based on the output torque of the reducer of the left mechanism, the output torque of the reducer of the right mechanism, and the reduction ratio of the reducers, the real-time power of the motor during the flipping process is predicted. The maximum power of the motor is obtained based on the real-time power of the motor. The structure of the flipping machine is optimized based on the predicted power consumption and the maximum power of the motor.

7. The structural optimization method based on predicted power consumption of a flip-board machine as described in claim 6, characterized in that, The output torque of the left-side mechanism reducer of the flipping machine, obtained based on the aforementioned equipment parameters and load parameters, includes: The horizontal angle of the left crank is obtained based on the angle between the left crank and the horizontal direction when the initial boom is horizontal and the rotation angle of the reducer output shaft. The two-dimensional coordinates of the left crank pivot point are obtained based on the horizontal angle of the left crank. The two-dimensional coordinates of the left rocker arm rotation hinge point are obtained based on the two-dimensional coordinates of the left crank rotation hinge point and the left flap arm rotation hinge point. Based on the two-dimensional coordinates of the left crank rotation pivot point, the left tilting arm rotation pivot point, and the left rocker rotation pivot point, the angle between the left rocker and the horizontal direction, the angle between the left rocker and the horizontal direction at the initial position, the angle between the left transmission rod and the horizontal direction, and the distance from the reducer output shaft to the left transmission rod are obtained. Based on the two-dimensional coordinates of the left crank rotation pivot point, the two-dimensional coordinates of the left rocker rotation pivot point, and the two-dimensional coordinates of the reducer output shaft, the torque of the load steel plate on the origin is obtained. Based on the mass of the load steel plate, the initial distance between the center of mass of the load steel plate and the pivot point of the left rocker arm, the horizontal angle between the center of mass of the load steel plate and the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the load steel plate on the pivot point of the left rocker arm is obtained. Based on the number of left cantilever arms, the mass of the left cantilever arms, the distance between the center of mass of the left cantilever arms and the pivot point of the left rocker arm at the initial position, the horizontal angle between the initial center of mass of the left cantilever arms and the pivot point of the left rocker arm, the angle between the left rocker arm and the horizontal direction, and the angle between the left rocker arm and the horizontal direction at the initial position, the rotational torque of the left cantilever arms on the pivot point of the left rocker arm is obtained. Based on the mass of the left joystick, the distance between the center of mass of the left joystick and the pivot point of the left joystick, and the angle between the left joystick and the horizontal direction, the rotational torque of the left joystick about the pivot point of the left joystick is obtained. Based on the rotational torque of the load steel plate on the left rocker arm's pivot point, the rotational torque of the left cantilever on the left rocker arm's pivot point, the rotational torque of the left rocker arm on the left rocker arm's pivot point, the distance from the reducer output shaft to the left transmission rod, the mass of the left transmission rod, the distance between the center of mass of the left transmission rod and the connection point of the left rocker arm, the angle between the left transmission rod and the horizontal direction, and the angle between the left rocker arm and the horizontal direction, the output torque of the reducer of the left mechanism of the flipping machine is obtained.

8. The structural optimization method based on predicted power consumption of a flip-board machine as described in claim 6, characterized in that, The output torque of the right-side mechanism reducer of the flipping machine, obtained based on the aforementioned equipment parameters and load parameters, includes: The horizontal angle of the right crank is obtained based on the angle between the right crank and the horizontal direction when the initial boom is horizontal and the rotation angle of the reducer output shaft. The two-dimensional coordinates of the right crank pivot point are obtained based on the horizontal angle of the right crank. The two-dimensional coordinates of the right rocker arm rotation hinge point are obtained based on the two-dimensional coordinates of the right crank rotation hinge point and the right flap arm rotation hinge point. Based on the two-dimensional coordinates of the right crank rotation pivot point, the right tilting arm rotation pivot point, and the right rocker rotation pivot point, the angle between the right rocker and the horizontal direction, the angle between the right rocker and the horizontal direction at the initial position, the angle between the right transmission rod and the horizontal direction, and the distance from the reducer output shaft to the right transmission rod are obtained. Based on the two-dimensional coordinates of the right crank pivot point, the two-dimensional coordinates of the right rocker pivot point, and the two-dimensional coordinates of the reducer output shaft, the torque of the load steel plate on the origin is obtained. Based on the mass of the load steel plate, the initial distance between the center of mass of the load steel plate and the pivot point of the right rocker arm, the horizontal angle between the center of mass of the load steel plate and the pivot point of the right rocker arm, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position, the rotational torque of the load steel plate on the pivot point of the right rocker arm is obtained. Based on the number of right cantilever arms, the mass of the right cantilever arms, the distance between the center of mass of the right cantilever arms and the pivot point of the right rocker arm at the initial position, the horizontal angle between the initial center of mass of the right cantilever arms and the pivot point of the right rocker arm, the angle between the right rocker arm and the horizontal direction, and the angle between the right rocker arm and the horizontal direction at the initial position, the rotational torque of the right cantilever arms on the pivot point of the right rocker arm is obtained. Based on the mass of the right rocker, the distance between the center of mass of the right rocker and the pivot point of the right rocker, and the angle between the right rocker and the horizontal direction, the rotational torque of the right rocker about the pivot point of the right rocker is obtained. Based on the rotational torque of the load steel plate on the right rocker arm's rotational pivot point, the rotational torque of the right cantilever on the right rocker arm's rotational pivot point, the rotational torque of the right rocker arm on the right rocker arm's rotational pivot point, the distance from the reducer output shaft to the right transmission rod, the mass of the right transmission rod, the distance between the center of mass of the right transmission rod and the connection point of the right rocker arm, the angle between the right transmission rod and the horizontal direction, and the angle between the right rocker arm and the horizontal direction, the output torque of the reducer of the right mechanism of the flipping machine is obtained.

9. The structural optimization method based on predicted power consumption of a flip-board machine as described in claim 6, characterized in that, The method of obtaining the predicted power consumption of the tilting machine in one tilting cycle based on the output torque of the left mechanism reducer and the output torque of the right mechanism reducer includes: The predicted power consumption of the flipping machine in one flipping cycle is obtained by integrating the output torque of the reducer of the left mechanism and the output torque of the reducer of the right mechanism over the flipping cycle.

10. The structural optimization method based on predicted power consumption of a flip-board machine as described in claim 6, characterized in that, The optimization of the flip-board machine structure based on the predicted power consumption and the maximum power of the motor includes: Adjust the equipment parameters and the load parameters to reduce the predicted power consumption, and select the motor for the flipping machine based on the maximum power of the motor.

11. A fault detection device based on predicted power consumption of a flip-board machine, characterized in that, The device includes: The parameter acquisition unit is used to acquire the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process. The torque acquisition unit is used to obtain the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters. The power consumption prediction unit is used to obtain the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the reducer of the left mechanism and the output torque of the reducer of the right mechanism. The fault analysis unit is used to compare the predicted power consumption with the actual power consumption, and to determine whether the motor of the flipping machine has a fault based on the comparison result.

12. A structural optimization device based on predicting power consumption of a flip-board machine, characterized in that, The device includes: The parameter acquisition unit acquires the equipment parameters of the flipping machine and the load parameters of the load steel plate during the flipping process; The torque acquisition unit obtains the output torque of the left mechanism reducer and the output torque of the right mechanism reducer of the flipping machine based on the equipment parameters and load parameters. The power consumption prediction unit obtains the predicted power consumption of the flipping machine in one flipping cycle based on the output torque of the reducer of the left mechanism and the output torque of the reducer of the right mechanism. The real-time power prediction unit predicts the real-time power of the motor during the flipping process based on the output torque of the reducer of the left mechanism, the output torque of the reducer of the right mechanism, and the reduction ratio of the reducer. The maximum power acquisition unit is used to obtain the maximum power of the motor based on the real-time power of the motor. The structure optimization unit is used to optimize the structure of the flipping machine based on the predicted power consumption and the maximum power of the motor.

13. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1-10.

14. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1-10.

15. A computer program product comprising a computer program / instructions, characterized in that, When the computer program / instructions are executed by the processor, they implement the steps of the method according to any one of claims 1 to 10.

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