Dynamic monitoring system for stress state of metal structure of crane

Abstract

The utility model discloses a dynamic monitoring system for the stress state of a metal structure of a crane, relates to the technical field of stress detection of metal structures of cranes, and can better reflect the relation between the stress state and the cargo running state when the crane hoists different types of cargoes. The dynamic monitoring system for the stress state of the metal structure of the crane comprises a monitoring terminal, a stress monitoring module mounted on the metal structure of the crane and a motion monitoring module mounted on hoisted goods, the monitoring terminal is used for receiving data sent by the stress monitoring module and the motion monitoring module, converting the received data into stress data and motion acceleration data and displaying the stress data and the motion acceleration data; the stress monitoring module is composed of a stress measuring circuit in a circuit board packaging structure and a strain gauge packaging module, and is used for collecting strain data of a strain gauge pasting position in real time. The motion monitoring module is of a circuit board packaging structure and is used for collecting motion axis acceleration data of hoisted goods in real time.

Description

Technical Field

[0001] The utility model relates to the technical field of crane metal structure stress detection, in particular to a crane metal structure stress state dynamic monitoring system. Background Art

[0002] At present, regular stress testing of the metal structures of cranes in use is of great significance to ensure the safe operation of cranes and reduce the occurrence of failures. The theoretical calculation results of stress levels and strength reserves in crane metal structures are often affected by factors such as empirical coefficients, simplified calculation models, and damage caused during transportation, installation, and use, and there are large errors compared with the actual situation. In daily use, due to improper operation, environmental corrosion, design and installation defects, etc., the metal structure of the crane will inevitably have tiny hidden damage as the use time increases. Stress testing can help detect these potential damages and find out the causes of the damage, providing guidance for the repair of metal structures.

[0003] In the prior art, stress detection of metal structures of cranes is usually performed by pasting strain gauges on the parts to be detected when the crane is in a stopped state, and performing stress detection with the help of a multi-channel stress detector when the crane is loaded and running.

[0004] However, the inventors of the present application have found that this method has the following defects:

[0005] (1) The detection process is time-consuming, which will cause the crane equipment to be unusable for a long time. For large cranes, some metal structures such as inclined rods and bottom plates under beams are difficult to directly access, and the strain gauges need to be pasted with the help of special equipment such as ladders. After completing a stress measurement, the strain gauges are easily damaged by rain erosion, grease pollution, mechanical wear, etc. due to the lack of external protective structures, and the reuse rate is low. When performing stress testing for the second time, the strain gauge pasting work needs to be carried out again, which seriously reduces the efficiency of crane stress testing.

[0006] (2) The intelligence level of the stress detection process is not enough to meet the needs of long-term online stress monitoring. In the existing stress detection methods, the crane loading and data collection process must be implemented with the help of manual operation, which is not enough to realize the automatic collection of stress data in an unmanned state. At the same time, when collecting stress, the movement data of the hoisted cargo is not synchronized. The crane stress detection includes the entire process of cargo lifting, horizontal movement, and cargo lowering. The stress data currently obtained is separated from the movement state of the cargo, and it is impossible to analyze the relationship between the abnormal stress state and the crane operation state.

[0007] Therefore, how to provide a dynamic monitoring system for the stress state of the crane's metal structure, which can perform long-term monitoring of the stress state of its metal structure under normal operation of the crane, and the collection of stress data can be carried out automatically, and the collected data can be synchronized with the operating status of the hoisted cargo, has become a technical problem that technical personnel in this field urgently need to solve. Utility Model Content

[0008] The purpose of the utility model is to provide a dynamic monitoring system for the stress state of a crane metal structure, which can better reflect the relationship between the stress state and the running state of the cargo when the crane lifts different types of cargo, thereby helping to avoid the occurrence of excessive stress in the metal structure due to improper cargo lifting.

[0009] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0010] A crane metal structure stress state dynamic monitoring system comprises: a monitoring terminal, a stress monitoring module installed on the crane metal structure, and a motion monitoring module installed on the hoisted cargo, wherein the stress monitoring module and the motion monitoring module are connected to the monitoring terminal through WiFi wireless communication and transmit data;

[0011] The monitoring terminal adopts a computer, which is used to receive the data sent by the stress monitoring module and the motion monitoring module, and convert the received data into stress data and motion acceleration data respectively and display them; the stress monitoring module is composed of a stress measurement circuit and a strain gauge packaging module in a circuit board packaging structure, which is used to collect strain data of the strain gauge pasting position in real time and send the data to the monitoring terminal; the motion monitoring module adopts a circuit board packaging structure, which is used to collect the acceleration data of the motion axis of the hoisted cargo in real time, and send the data to the monitoring terminal;

[0012] The strain gauge packaging module includes: a sealing tool, and a strain gauge arranged inside the sealing tool, and the strain gauge is pasted on the metal structure body of the crane, and the sealing tool presses the strain gauge packaging module to the surface of the metal structure by magnetic attraction;

[0013] The circuit board packaging structure includes: a sealing box, and an upper cover plate and a side cover plate adapted to the sealing box; the surface of the sealing box is provided with a sealing groove, and a sealing ring is installed in the sealing groove; the two sides of the sealing box are respectively provided with mounting grooves, and a permanent magnet is installed in each mounting groove and fixed by the side cover plate.

[0014] In actual application, the sealing tool has a lead hole, and the lead hole is used to pass the connecting wire of the strain gauge, and the lead hole is sealed with a sealant;

[0015] The sealing tool has a sealing groove, and the sealing groove is used to install a sealing ring;

[0016] The sealing tool has a permanent magnet mounting hole, and the permanent magnet mounting hole is used to mount a cylindrical NdFeB permanent magnet.

[0017] In actual application, the sealing box has a wire outlet hole, and the wire outlet hole is used to pass the charging wire of the lithium-ion battery and / or the connecting wire of the strain gauge, and the wire outlet hole is finely sealed with waterproof glue.

[0018] Wherein, the upper cover plate and the sealing box are connected by screws, and the side cover plate and the sealing box are fixed by screws.

[0019] Specifically, the circuit board and the lithium-ion battery for power supply are fixed by gluing or positioning with screws.

[0020] Furthermore, the sealing box, the upper cover plate and the side cover plate are all made of aluminum alloy, and the permanent magnet is made of neodymium iron boron.

[0021] Furthermore, the end of the charging wire of the lithium-ion battery is provided with a waterproof rubber cap, and the connecting wire of the strain gauge is provided with a waterproof heat shrink soldering ring.

[0022] Compared with the prior art, the crane metal structure stress state dynamic monitoring system described in the utility model has the following advantages:

[0023] The crane metal structure stress state dynamic monitoring system provided by the utility model first grinds off the paint layer of the crane metal structure to be monitored by a grinder until the metal structure body is exposed, and then glues the strain gauge to the crane metal structure body. Then, different monitoring modules are selected for setting according to different monitoring scenarios; for example:

[0024] Active monitoring mode: It means that the crane operation and maintenance or inspection personnel actively carry out stress monitoring in a specific monitoring cycle or when they suspect that the crane metal structure may have excessive stress. When stress monitoring starts, the crane is in a test working state and lifts specific goods according to the requirements of the monitoring personnel. In this mode, the motion monitoring module is adsorbed on the outer wall of the cargo container to be lifted, the monitoring terminal is started, and the WIFI connection between the monitoring terminal and the stress monitoring module and the motion monitoring module is completed. The driver operates the crane to lift the goods, move the goods horizontally, and lower and unload the goods. The stress monitoring module and the motion monitoring module send the strain gauge voltage change data and the three-dimensional acceleration data of the lifted goods respectively. After the signal conversion, the host computer of the monitoring terminal displays the change curve of the stress of the detected metal structure and the three-dimensional acceleration data of the lifted goods with the monitoring time.

[0025] Key cargo sampling monitoring mode: It refers to monitoring the stress changes of metal structures when the crane is lifting cargo of special size or special weight. When stress monitoring starts, the crane is in a normal state of continuous cargo lifting. In this mode, the monitoring terminal, motion monitoring module and stress monitoring module are all in a dormant state. The tester will attach the motion monitoring module to the cargo to be monitored in advance. When the crane lifts the cargo, the motion monitoring module detects significant changes in the three-dimensional acceleration of the cargo, especially the acceleration in the vertical direction to the ground. At this time, the motion monitoring module sends a signal to wake up the monitoring terminal, and the monitoring terminal then sends a signal to wake up the stress monitoring module. Block, the motion monitoring module and the stress monitoring module start to send the strain gauge voltage change data and the three-dimensional acceleration data of the hoisted goods to the monitoring terminal respectively; when the goods are hoisted, and the three-dimensional acceleration data of the goods has no obvious change within a certain period of time, the monitoring terminal, the motion monitoring module and the stress monitoring module are in a dormant state here; in this mode, multiple motion monitoring modules can be set to be adsorbed on multiple goods to be monitored respectively, and when the crane hoists different goods, their respective three-dimensional acceleration data and stress change data are recorded respectively; after the motion monitoring module is adsorbed, continuous monitoring of multiple special goods can be completed without human monitoring;

[0026] Long-term monitoring mode: It is suitable for cranes that hoist relatively fixed types of goods and need to obtain the stress state information of the crane's metal structure continuously for a long time. In this mode, the motion monitoring module is adsorbed on the side cover plate on the upper part of the crane hook, and the acceleration state of the hoisted goods is approximately reflected by monitoring the three-dimensional acceleration data of the crane hook; the stress monitoring module continuously monitors the stress changes of the crane's metal structure;

[0027] From this analysis, it can be seen that the dynamic monitoring system for the stress state of the metal structure of the crane provided by the utility model can better reflect the relationship between the stress state and the operating state of the cargo when the crane is lifting different types of cargo, thereby helping to avoid the occurrence of excessive stress in the metal structure due to improper lifting of the cargo; in addition, when the crane is operating normally, the stress state of its metal structure can be monitored for a long time, and the collection of stress data can be automatic, and the collected data can be synchronized with the operating state of the hoisted cargo. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A schematic structural diagram of a circuit board packaging structure in a crane metal structure stress state dynamic monitoring system provided by an embodiment of the utility model;

[0029] Figure 2 A schematic diagram of the exploded structure of the circuit board packaging structure in the crane metal structure stress state dynamic monitoring system provided by the embodiment of the utility model;

[0030] Figure 3 A first-view structural diagram of a strain gauge packaging module in a crane metal structure stress state dynamic monitoring system provided by an embodiment of the utility model;

[0031] Figure 4 A second perspective structural schematic diagram of a strain gauge packaging module in a crane metal structure stress state dynamic monitoring system provided by an embodiment of the utility model;

[0032] Figure 5 A circuit schematic diagram of a stress monitoring module in a crane metal structure stress state dynamic monitoring system provided by an embodiment of the utility model;

[0033] Figure 6 A circuit schematic diagram of a motion monitoring module in a crane metal structure stress state dynamic monitoring system provided by an embodiment of the utility model.

[0034] Reference numerals:

[0035] 1-sealing box; 11-wire outlet hole; 2-upper cover; 3-side cover; 4-permanent magnet; 5-sealing tooling; 51-lead hole; 52-sealing groove; 53-permanent magnet mounting hole. DETAILED DESCRIPTION

[0036] For ease of understanding, the crane metal structure stress state dynamic monitoring system provided by the embodiment of the utility model is described in detail below in conjunction with the accompanying drawings of the specification.

[0037] The utility model provides a crane metal structure stress state dynamic monitoring system. Figure 1-Figure 4As shown, it includes: a monitoring terminal, a stress monitoring module installed on the metal structure of the crane, and a motion monitoring module installed on the hoisted cargo, and the stress monitoring module and the motion monitoring module are connected to the monitoring terminal through WiFi wireless communication and transmit data;

[0038] The monitoring terminal adopts a computer, which is used to receive the data sent by the stress monitoring module and the motion monitoring module, and convert the received data into stress data and motion acceleration data respectively and display them; the stress monitoring module is composed of a stress measurement circuit and a strain gauge packaging module in a circuit board packaging structure, which is used to collect the strain data of the strain gauge pasting position in real time and send the data to the monitoring terminal; the motion monitoring module adopts a circuit board packaging structure, which is used to collect the acceleration data of the motion axis of the hoisted cargo in real time and send the data to the monitoring terminal;

[0039] The strain gauge packaging module includes: a sealing tool 5, and a strain gauge arranged inside the sealing tool 5, and the strain gauge is pasted on the metal structure body of the crane, and the sealing tool 5 presses the strain gauge packaging module to the surface of the metal structure through magnetic attraction;

[0040] The circuit board packaging structure includes: a sealing box 1, and an upper cover plate 2 and a side cover plate 3 adapted to the sealing box 1; the surface of the sealing box 1 has a sealing groove, and a sealing ring is installed in the sealing groove; the two sides of the sealing box 1 have mounting grooves respectively, and a permanent magnet 4 is installed in each mounting groove and fixed by the side cover plate 3.

[0041] Compared with the prior art, the crane metal structure stress state dynamic monitoring system described in the embodiment of the utility model has the following advantages:

[0042] The crane metal structure stress state dynamic monitoring system provided by the embodiment of the utility model is used to first grind off the paint layer of the crane metal structure to be monitored by a grinder until the metal structure body is exposed, and then use glue to stick the strain gauge to the crane metal structure body, and then select different monitoring modules for setting according to different monitoring scenarios; for example:

[0043] Active monitoring mode: It means that the crane operation and maintenance or inspection personnel actively carry out stress monitoring in a specific monitoring cycle or when they suspect that the crane metal structure may have excessive stress. When stress monitoring starts, the crane is in a test working state and lifts specific goods according to the requirements of the monitoring personnel. In this mode, the motion monitoring module is adsorbed on the outer wall of the cargo container to be lifted, the monitoring terminal is started, and the WIFI connection between the monitoring terminal and the stress monitoring module and the motion monitoring module is completed. The driver operates the crane to lift the goods, move the goods horizontally, and lower and unload the goods. The stress monitoring module and the motion monitoring module send the strain gauge voltage change data and the three-dimensional acceleration data of the lifted goods respectively. After the signal conversion, the host computer of the monitoring terminal displays the change curve of the stress of the detected metal structure and the three-dimensional acceleration data of the lifted goods with the monitoring time.

[0044] Key cargo sampling monitoring mode: It refers to monitoring the stress changes of metal structures when the crane is lifting cargo of special size or special weight. When stress monitoring starts, the crane is in a normal state of continuous cargo lifting. In this mode, the monitoring terminal, motion monitoring module and stress monitoring module are all in a dormant state. The tester will attach the motion monitoring module to the cargo to be monitored in advance. When the crane lifts the cargo, the motion monitoring module detects significant changes in the three-dimensional acceleration of the cargo, especially the acceleration in the vertical direction to the ground. At this time, the motion monitoring module sends a signal to wake up the monitoring terminal, and the monitoring terminal then sends a signal to wake up the stress monitoring module. Block, the motion monitoring module and the stress monitoring module start to send the strain gauge voltage change data and the three-dimensional acceleration data of the hoisted goods to the monitoring terminal respectively; when the goods are hoisted, and the three-dimensional acceleration data of the goods has no obvious change within a certain period of time, the monitoring terminal, the motion monitoring module and the stress monitoring module are in a dormant state here; in this mode, multiple motion monitoring modules can be set to be adsorbed on multiple goods to be monitored respectively, and when the crane hoists different goods, their respective three-dimensional acceleration data and stress change data are recorded respectively; after the motion monitoring module is adsorbed, continuous monitoring of multiple special goods can be completed without human monitoring;

[0045] Long-term monitoring mode: It is suitable for cranes that hoist relatively fixed types of goods and need to obtain the stress state information of the crane's metal structure continuously for a long time. In this mode, the motion monitoring module is adsorbed on the side cover plate on the upper part of the crane hook, and the acceleration state of the hoisted goods is approximately reflected by monitoring the three-dimensional acceleration data of the crane hook; the stress monitoring module continuously monitors the stress changes of the crane's metal structure;

[0046] From this analysis, it can be seen that the dynamic monitoring system for the stress state of the metal structure of the crane provided by the embodiment of the utility model can better reflect the relationship between the stress state and the operating state of the cargo when the crane is lifting different types of cargo, thereby helping to avoid the occurrence of excessive stress in the metal structure due to improper cargo lifting; in addition, when the crane is operating normally, the stress state of its metal structure can be monitored for a long time, and the collection of stress data can be automatic, and the collected data can be synchronized with the operating state of the hoisted cargo.

[0047] In practical application, such as Figure 1-Figure 4 As shown, the sealing tool 5 may have a lead hole 51, and the lead hole 51 may be used to pass the connecting wire of the strain gauge, and the lead hole 51 may be sealed with sealant; the sealing tool 5 may have a sealing groove 52, and the sealing groove 52 may be used to install a sealing ring; the sealing tool 5 may have a permanent magnet mounting hole 53, and the permanent magnet mounting hole 53 may be used to install a cylindrical NdFeB permanent magnet, so that the strain gauge sealing tool is pressed to the surface of the metal structure by utilizing the magnetic attraction between the cylindrical NdFeB permanent magnet and the metal structure of the crane.

[0048] In practical application, such as Figure 1-Figure 4 As shown, the sealing box 1 may have a wire outlet hole 11, and the wire outlet hole 11 can be used to pass the charging wire of the lithium-ion battery and / or the connecting wire of the strain gauge, and the wire outlet hole 11 can be finely sealed with waterproof glue.

[0049] Among them, Figure 1-Figure 4 As shown, the upper cover plate 2 and the sealing box 1 can be connected by screws, and the side cover plate 3 and the sealing box 1 can be fixed by screws. When the connecting screws are tightened, the sealing ring can effectively prevent external water or other pollutants from entering the interior of the sealing box 1, thereby effectively avoiding the phenomenon of damaging the internally sealed circuit board.

[0050] Specifically, the circuit board and the lithium-ion battery for power supply can be fixed by gluing or fixing with screws.

[0051] Furthermore, if Figure 1-Figure 4 As shown, the sealing box 1, the upper cover plate 2 and the side cover plate 3 can all be made of aluminum alloy, and the permanent magnet 4 can be made of neodymium iron boron.

[0052] Furthermore, if Figure 1-Figure 4 As shown, the charging lead end of the above-mentioned lithium-ion battery can be provided with a waterproof rubber cap to effectively prevent corrosion from rain and humid air; the connecting lead of the above-mentioned strain gauge can be provided with a waterproof heat shrink soldering ring.

[0053] Figure 5The circuit schematic diagram of the stress state dynamic monitoring system includes a strain gauge measurement circuit. The strain gauge is connected in a 1 / 4 bridge mode. The two wires of the strain gauge are connected to the P1 and P2 interfaces respectively. R1, R2, R3 and the strain gauge form a Wheatstone bridge. The U1 chip model is MAX1452, which is responsible for voltage excitation of the Wheatstone bridge, measuring the voltage change at both ends of the strain gauge caused by the change of the stress state of the crane metal structure, and outputting it from the OUT pin. The three pins INM, BDR and INP of the U1 chip are respectively connected to the three nodes of the Wheatstone bridge, and the fourth node of the Wheatstone bridge is connected to the digital ground.

[0054] The voltage signal output from the OUT pin of the U1 chip is converted from an analog signal to a digital signal, and is sent to the host computer of the monitoring terminal for processing and display via wireless WIFI transmission; the model of chip U3 is MAX6126AASA25, and its function is to provide a stable reference voltage for the U2 chip; its input voltage is 3.3V, and its output voltage is 2.5V, and its OUTS pin is connected to the REF pin of the U2 chip; the model of the U2 chip is MAX1134, and its function is to collect the voltage signal output from the OUT pin of the U1 chip, and its AIN pin is connected to the OUT pin of the U1 chip, and its DOUT, SCLK, DIN, and CS# pins are respectively connected to the IO33, IO32, IO35, and IO34 pins of the U9 chip; the model of the U9 chip is ESP32-S3, and its function is to receive the data signal sent by the U2 chip and send the signal to the host computer of the remote monitoring terminal.

[0055] Figure 6 This is the circuit schematic diagram of the motion monitoring module, which is responsible for monitoring the three-dimensional motion of the hoisted goods, collecting the acceleration data of the goods in the three directions of X, Y and Z in real time, and sending it to the host computer of the remote monitoring terminal through WIFI; the model of the U12 chip is ADXL345, which is responsible for measuring the acceleration data of the goods in the three directions of X, Y and Z. Its CS#, INT1, INT2, NC, SDO, SDA and SCL pins are respectively connected to the IO27, IO26, IO25, IO33, IO32, IO35 and IO34 pins of the U11 chip; the model of the U11 chip is ESP32-S3, which is used to receive the data signal sent by the U12 chip and send the signal to the host computer of the remote monitoring terminal;

[0056] The host computer receives the data values ​​and corresponding sampling time sent by the U9 and U12 chips, and simultaneously displays on the screen the curves of the change of the crane metal structure stress and the three-dimensional acceleration data of the hoisted cargo as the sampling time changes; among them, the data received from the U9 chip is the voltage change value near the strain gauge pasting position, and this value is converted into a stress value.

[0057] The above is only a specific implementation of the utility model, but the protection scope of the utility model is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed by the utility model, which should be included in the protection scope of the utility model. Therefore, the protection scope of the utility model should be based on the protection scope of the claims.

Claims

1. A crane metal structure stress state dynamic monitoring system, characterized in that: include: A monitoring terminal, a stress monitoring module installed on the metal structure of the crane, and a motion monitoring module installed on the hoisted cargo, wherein the stress monitoring module and the motion monitoring module are connected to the monitoring terminal via WiFi wireless communication and transmit data; The monitoring terminal adopts a computer, which is used to receive the data sent by the stress monitoring module and the motion monitoring module, and convert the received data into stress data and motion acceleration data respectively and display them; the stress monitoring module is composed of a stress measurement circuit and a strain gauge packaging module in a circuit board packaging structure, which is used to collect strain data of the strain gauge pasting position in real time and send the data to the monitoring terminal; the motion monitoring module adopts a circuit board packaging structure, which is used to collect the acceleration data of the motion axis of the hoisted cargo in real time, and send the data to the monitoring terminal; The strain gauge packaging module includes: a sealing tool, and a strain gauge arranged inside the sealing tool, and the strain gauge is pasted on the metal structure body of the crane, and the sealing tool presses the strain gauge packaging module to the surface of the metal structure by magnetic attraction; The circuit board packaging structure includes: a sealing box, and an upper cover plate and a side cover plate adapted to the sealing box; the surface of the sealing box is provided with a sealing groove, and a sealing ring is installed in the sealing groove; the two sides of the sealing box are respectively provided with mounting grooves, and a permanent magnet is installed in each mounting groove and fixed by the side cover plate.

2. The crane metal structure stress state dynamic monitoring system according to claim 1 is characterized in that: The sealing tool has a lead hole, and the lead hole is used to pass the connecting wire of the strain gauge, and the lead hole is sealed with a sealant; The sealing tool has a sealing groove, and the sealing groove is used to install a sealing ring; The sealing tool has a permanent magnet mounting hole, and the permanent magnet mounting hole is used to mount a cylindrical NdFeB permanent magnet.

3. The crane metal structure stress state dynamic monitoring system according to claim 1 is characterized in that: The sealing box has a wire outlet hole, and the wire outlet hole is used to pass the charging wire of the lithium-ion battery and / or the connecting wire of the strain gauge, and the wire outlet hole is finely sealed with waterproof glue.

4. The crane metal structure stress state dynamic monitoring system according to claim 1 or 3, characterized in that: The upper cover plate is connected to the sealing box via screws, and the side cover plate is fixed to the sealing box via screws.

5. The crane metal structure stress state dynamic monitoring system according to claim 4 is characterized in that: The circuit board and the lithium-ion battery for power supply are fixed by gluing or positioning with screws.

6. The crane metal structure stress state dynamic monitoring system according to claim 5 is characterized in that: The sealing box, the upper cover plate and the side cover plate are all made of aluminum alloy, and the permanent magnet is made of neodymium iron boron.

7. The crane metal structure stress state dynamic monitoring system according to claim 3 is characterized in that: The charging lead end of the lithium-ion battery is provided with a waterproof rubber cap, and the connecting lead of the strain gauge is provided with a waterproof heat shrink soldering ring.

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