Device for detecting crack and fatigue life of crane girder

Abstract

The utility model discloses a device for detecting cracks and fatigue life of a main beam of a crane. The device mainly comprises an upper computer and a lower computer, the upper computer is a tablet computer or a computer with data receiving, storing, processing and controlling functions, the lower computer is a detection trolley with detecting, moving and cleaning functions, and the upper computer and the lower computer are communicated and controlled in a wireless mode; due to the adoption of the movable detection trolley, each position of the crane can be reached, the position of the crack can be accurately identified, and the efficiency is far higher than that of manual inspection; and the suspicious crack position is cleaned, so that the accuracy of fatigue crack identification is greatly improved.

Description

Technical Field

[0001] The utility model relates to the technical field of crane detection, in particular to a device for detecting cracks and fatigue life of a crane main beam. Background Art

[0002] Existing crane structures, especially load-bearing structures such as main beams, are prone to fatigue cracks due to long-term repeated operation under various loads. The expansion of these cracks not only shortens the service life of structures such as main beams, but may also cause safety hazards. Therefore, how to effectively detect fatigue cracks and fatigue life of crane structures has become an urgent problem to be solved. For example, through real-time detection, fatigue cracks in the structure can be discovered and handled in time, and effective measures can be taken to slow down the expansion of fatigue cracks in the load-bearing structure, which can greatly reduce the risk of fatigue failure of the crane, extend the fatigue service life of the structure, and improve the safety of the crane.

[0003] After the crane is put into use, the crack inspection is mainly carried out by technicians. After the technicians board the crane, they inspect each part of the crane one by one. With this method, the inspection results can truly reflect the distribution of cracks in the crane.

[0004] The main disadvantages of manual inspection methods are: it mainly relies on the experience and skills of the inspectors, the labor intensity is high, there are safety hazards when the crane is high, the efficiency is low, some parts of the crane are difficult to reach and difficult to inspect, and real-time inspection cannot be achieved. At present, there is no efficient equipment and method for real-time detection of fatigue cracks and calculation of fatigue life. Summary of the invention

[0005] The purpose of the utility model is to overcome the shortcomings of the above-mentioned background technology and to provide a device and method for crane fatigue crack and fatigue life detection. The device is simple, convenient and easy to implement, and can detect cracks in real time and discover fatigue hazards in time.

[0006] The technical solution of the utility model is: a device for detecting cracks and fatigue life of a crane main beam, the device mainly consisting of a host computer and a slave computer; the host computer is a tablet or computer with data receiving, storage, processing and control functions, the slave computer is a detection trolley with detection, movement and cleaning functions, and the host computer and the slave computer are connected and controlled wirelessly.

[0007] The detection vehicle is composed of a front vehicle and a rear vehicle, and the front vehicle is fixedly connected to the rear vehicle through a connecting device;

[0008] The front vehicle is composed of a driving wheel, a retractable cleaning device, a camera, an air suction cup II, a steel pull rope, and a battery. Four driving wheels are arranged at the bottom of the front vehicle, and retractable cleaning devices are arranged at both ends of the left side of the front vehicle. An air suction cup II is arranged at the bottom of the front vehicle, and cameras and connection points are arranged on the air suction cup II. A connection device for connecting to a rear vehicle is arranged at the right side of the front vehicle;

[0009] The rear vehicle is composed of a driving wheel, a steel pull rope, a top rod, a drum, a motor, a battery, a ground mode signal light, a wall climbing mode signal light, an obstacle crossing mode signal light, and a charging port. A connecting device connected to the front vehicle is provided at the left side of the rear vehicle, and four driving wheels are provided at the bottom. An air suction cup I is provided at the left side of the bottom of the rear vehicle, and a top rod is provided on the air suction cup I. A drum, a motor and a battery are provided at the right side of the top of the rear vehicle. A steel pull rope is provided on the drum, and one end of the steel pull rope is connected to the drum, and the other end passes through the top rod and is fixedly connected to the front vehicle connection point; three side-by-side mode signal lights are provided at the right side of the rear vehicle, namely, a ground mode signal light, a wall climbing mode signal light, and an obstacle crossing mode signal light, and a convenient charging port for charging the battery is also provided. When the ground remote control is operated, the mode signal light is lit when a certain mode is selected.

[0010] The front car and the rear car are respectively provided with a main control board and a driving board. The two main control boards can communicate with each other, and the main control boards are connected to the driving boards; the main control boards are connected to the APC220 wireless remote control module, etc.; the front car is also provided with an ultrasonic obstacle avoidance module.

[0011] Compared with the prior art, the utility model has the following advantages:

[0012] 1. Accurate identification of cracks: Due to the use of a movable inspection trolley, it can reach various positions of the crane and accurately identify the location of the cracks, and the efficiency is much higher than manual inspection.

[0013] 2. Crack surface cleaning function: Since the movable inspection trolley is equipped with a cleaning device, the suspected crack position can be cleaned, which greatly improves the accuracy of crack identification.

[0014] 3. High passability: The detection vehicle adopts a deformable front and rear vehicle structure, with ground mode, wall climbing mode, and obstacle crossing mode, and can pass through complex areas. The lens adopts a retractable, bendable and rotatable bracket form, which greatly increases the detection range. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the structure of the utility model;

[0016] Figure 2 This is a schematic diagram of the front vehicle structure of the utility model

[0017] Figure 3This is a schematic diagram of the rear vehicle structure of the utility model

[0018] Among them: 1. retractable cleaning device, 2. camera, 3. steel pull rope, 4. top rod, 5. reel, 6. motor, 7. charging port, 8. ground mode signal light, 9. wall climbing mode signal light, 10. obstacle crossing mode signal light, 11. battery, 12. air suction cup I, 13. connecting device, 14. connecting point, 15. air suction cup II, 16. driving wheel, 17. main control board, 18. driving board. DETAILED DESCRIPTION

[0019] This embodiment is a device for detecting cracks and fatigue life of crane main beams, which is mainly composed of a host computer and a slave computer; the host computer is a tablet computer with data receiving, storage, processing and control functions, and the slave computer is a detection vehicle with detection, movement and cleaning functions. The host computer and the slave computer are connected and controlled wirelessly.

[0020] like Figure 1 , Figure 2 , Figure 3 As shown, the detection vehicle is composed of a front vehicle and a rear vehicle, and the front vehicle is fixedly connected to the rear vehicle through a connecting device;

[0021] The front vehicle is composed of a driving wheel (16), a retractable cleaning device (1), a camera (2), and an air suction cup II (15). Four driving wheels (16) are arranged at the bottom of the front vehicle. The retractable cleaning devices (1) are arranged at both ends of the left side of the front vehicle. An air suction cup II (15) is arranged at the bottom of the front vehicle. The camera (2) and a connection point (14) are arranged on the air suction cup II (15). A connection device (13) for connecting to a rear vehicle is arranged at the right side of the front vehicle.

[0022] The rear vehicle is composed of a driving wheel (16), a steel pull rope (3), a top rod (4), a reel (5), a motor (6), a battery (11), a ground mode signal light (8), a wall climbing mode signal light (9), an obstacle crossing mode signal light (10), and a charging port (7). A connecting device (13) connected to the front vehicle is provided at the left side of the rear vehicle, four driving wheels (16) are provided at the bottom, an air suction cup I (12) is provided at the left side of the bottom of the rear vehicle, and a top rod (4) is provided on the air suction cup I (12). A reel (5), an electric motor (6) and a battery (11) are provided on the right side of the top of the rear vehicle. A steel pull rope (3) is provided on the reel (5). One end of the steel pull rope (3) is connected to the reel (5), and the other end passes through the top rod (4) and is fixedly connected to the connection point of the front vehicle. Three side-by-side mode signal lights are provided on the right side of the rear vehicle, namely a ground mode signal light (8), a wall climbing mode signal light (9), and an obstacle crossing mode signal light (10). A convenient charging port for charging the battery is also provided.

[0023] The front vehicle and the rear vehicle are each provided with a main control board (17), a driving board (18) and a battery pack (11); the two main control boards can communicate with each other using an I2C bus wired along a connecting device 13; the main control board (17) is connected to the driving board (18); the main control board (17) is connected to a wireless remote control module; and the front vehicle is also provided with an ultrasonic obstacle avoidance module.

[0024] The LabVIEW host computer software is installed on a tablet or a computer, and the LabVIEW front panel, i.e., the operation interface, is designed. The operator operates the LabVIEW host computer software and uses the APC220 serial port wireless module to send remote control instructions to the Arduino controller on the trolley. The Arduino controller reads the operation command sent by the LabVIEW software and realizes the specified actions and behaviors in different modes through the driver board (18), including the movement of the trolley, the action of the suction cup, the rotation of the reel, etc., so that the trolley performs the specified behavior actions.

[0025] The structure of the main program of the LabVIEW host computer is a sequence structure + While loop + event structure. First, the serial port communication is initialized by setting the serial port number; then, the program enters the Whi1e loop and event structure, constantly detecting whether there are events that are responded to and executed; the event structure includes "forward", "backward", "turn left", "turn right" and "stop", "roll rotation", "roll stop", "suction cup action", "suction cup stop", etc. Finally, the serial port communication is closed. In the program flowchart, the corresponding communication protocol is formulated, the serial port is configured, and different commands are issued through the serial port according to different button presses. The lower computer Arduino receives the serial port receipt, parses the command code and executes the corresponding command.

[0026] During the specific operation, the upper computer sets the detection trolley in ground mode, that is, when the main beam surface is horizontal, the ground mode signal light (8) lights up. The front car air suction cup II (15) and the rear car air suction cup I (12) are not started. The detection trolley can move forward, backward or turn by selecting different buttons on the upper computer operation interface. When the camera (2) is powered, it will shoot the surface cracks of the crane and transmit the video and photos to the upper computer. A manually adjustable retractable, rotatable and bendable bracket is used below the camera. According to the actual situation of the crane on site, the height and angle of the bracket are manually adjusted before the inspection, and the shooting range is greatly increased compared with the fixed bracket. When the suspected crack position is covered with oil or the like, the retractable cleaning device (1) is operated on the upper computer operation interface, and the cleaning device lifting motor starts to work and lowers the device, and the brush under the cleaning device contacts the suspected crack surface. The detection trolley moves repeatedly, driving the brush to repeatedly clean the surface. After cleaning is completed, the cleaning device is selected to end the work on the upper computer operation interface, and the cleaning device lifting motor starts to rise and rotate to extend the cleaning device to the non-working position.

[0027] During the specific operation, when the upper computer sets the detection vehicle to operate in the wall climbing mode, the wall climbing mode signal light (9) lights up. The motors of the front vehicle air suction cup II (15) and the rear vehicle air suction cup I (12) drive the internal fan impellers to rotate at high speed, so that the air is discharged at high speed, and negative pressure is generated between the bottom of the detection vehicle and the wall, so that the detection vehicle can be vertically adsorbed onto the wall. The ultrasonic sensor of the obstacle avoidance module of the front vehicle can detect the distance to the surrounding obstacles and output pulses to the main control board (17) for processing. The motor (6) of the rear vehicle does not work, and the reel (5) does not rotate.

[0028] During the specific operation, when the trolley encounters an obstacle in front of it and needs to continue moving forward, the upper computer is manually set to the obstacle crossing mode, and the obstacle crossing mode signal light (10) is on. The motor (6) of the rear car works, driving the drum (5) to rotate, and the steel pull rope (3) pulls up the front car through the top rod (4). The front car suction cup air suction cup II (15) stops working, and the inspection trolley continues to move upward. When the front car is in a suitable position above the obstacle, the drum (5) rotates in the opposite direction, and the pull rope (3) lowers the front car through the top rod (4). The front car air suction cup II (15) resumes working, sucks the surface of the crane structure, and continues to move forward to drag the rear car up. The rear car air suction cup I (12) keeps working during the obstacle crossing process to ensure that the inspection trolley does not fall. After crossing the obstacle and reaching the horizontal surface of the main beam, the front and rear car suction cups stop working, and the inspection trolley can operate in the ground mode, and the ground mode signal light (8) is on.

[0029] During the specific operation, the camera (2) takes pictures of the surface cracks of the crane when it is powered on, and transmits the video and pictures to the host computer. The size, distribution position and shooting time of the cracks are measured or recorded, and the fatigue crack position can be accurately located. The fatigue life calculation button is selected on the host computer operation interface, and relevant data such as the crack size is input. The fatigue life of the crane can be calculated according to the fatigue life calculation formula.

Claims

1. A device for detecting cracks and fatigue life of crane main beams, characterized in that The device is mainly composed of an upper computer and a lower computer; the upper computer is a tablet or computer with data receiving, storage, processing and control functions, and the lower computer is a detection vehicle with detection, movement and cleaning functions. The upper computer and the lower computer are connected and controlled wirelessly; the detection vehicle is composed of a front vehicle and a rear vehicle, and the front vehicle is fixedly connected to the rear vehicle through a connecting device; the front vehicle is composed of a driving wheel, a retractable cleaning device, a camera, and an air suction cup II. Four driving wheels are arranged at the bottom of the front vehicle, and retractable cleaning devices are respectively arranged at the two ends of the left side of the front vehicle. An air suction cup II is arranged at the bottom of the front vehicle, and cameras and connection points are respectively arranged on the air suction cup II. A connecting device for connecting to the rear vehicle is arranged at the right side of the front vehicle; the The rear vehicle is composed of driving wheels, steel pull ropes, top rods, drums, electric motors, batteries, ground mode signal lights, wall climbing mode signal lights, obstacle crossing mode signal lights and charging ports. A connecting device connected to the front vehicle is provided at the left side of the rear vehicle, and four driving wheels are provided at the bottom. An air suction cup I is provided at the left side of the bottom of the rear vehicle, and a top rod is provided on the air suction cup I. A drum, electric motor and batteries are provided at the right side of the top of the rear vehicle. A steel pull rope is provided on the drum, and one end of the steel pull rope is connected to the drum, and the other end passes through the top rod and is fixedly connected to the connection point of the front vehicle. There are three side-by-side mode signal lights at the right side of the rear vehicle, which are a ground mode signal light, a wall climbing mode signal light and an obstacle crossing mode signal light. A convenient charging port for charging the battery is also provided.

2. A device for detecting cracks and fatigue life of crane main beams according to claim 1, characterized in that The front car and the rear car are respectively provided with a main control board and a driving board. The two main control boards can communicate with each other through an I2C bus. The main control boards are connected to the driving boards. The main control boards are connected to a wireless remote control module.

3. The device for detecting cracks and fatigue life of crane main beams according to claim 1 is characterized in that The front vehicle is also provided with an ultrasonic obstacle avoidance module.

Images