Device and system for detecting defects of lifting mechanism of crane

Abstract

The utility model discloses a defect detection device and a defect detection system for a crane lifting mechanism. The defect detection device comprises an acceleration measurement module, a broken wire detection module and a controller, the acceleration measurement module comprises a first acceleration sensor and a second acceleration sensor, the first acceleration sensor is mounted on the first side of the pulley, and the second acceleration sensor is mounted on the second side of the pulley; the broken wire detection module comprises a broken wire detection sensor and an analog-to-digital converter, the broken wire detection sensor surrounds the periphery of the steel wire rope, and the analog-to-digital converter is connected with the broken wire detection sensor; the controller is in communication connection with the acceleration measurement module and the broken wire detection module, and the controller is used for controlling the first acceleration sensor, the second acceleration sensor and the broken wire detection sensor to collect data. By integrating the first acceleration sensor, the second acceleration sensor and the broken wire detection sensor, the defects of the pulley groove and the steel wire rope are monitored in real time, and the safety and reliability of the crane lifting mechanism are improved.

Description

Technical Field

[0001] This utility model relates to the field of crane machinery testing technology, and in particular to a defect detection device and system for crane lifting mechanisms. Background Technology

[0002] As key components of crane lifting mechanisms, pulleys and wire ropes often suffer from wear, corrosion, and dirt accumulation due to harsh operating environments and long-term heavy loads. These issues can lead to problems such as pulley groove wear, wire rope breakage, and surface contamination. If these problems are not detected and addressed promptly, they will seriously threaten the normal operation of the crane, not only reducing its efficiency but also potentially causing serious safety accidents and incalculable losses to personnel and property.

[0003] Traditional inspection methods rely on manual visual inspection or the use of simple inspection tools, which are not only inefficient but also make it difficult to accurately determine the severity of defects, especially for minute defects hidden deep in the wheel groove or inside the wire rope, which are often not detected in time. Utility Model Content

[0004] This utility model aims to solve at least one of the technical problems existing in the prior art. To this end, this utility model proposes a defect detection device and system for crane lifting mechanisms. By integrating a first acceleration sensor, a second acceleration sensor, and a broken wire detection sensor, it realizes real-time monitoring of defects in the pulley grooves and wire ropes of the crane lifting mechanism, thereby improving the safety and reliability of the crane lifting mechanism and providing strong protection for the safe operation of the crane.

[0005] On one hand, this utility model embodiment provides a defect detection device for a crane lifting mechanism, the lifting mechanism including pulleys and wire ropes, and the detection device including:

[0006] An acceleration measurement module, comprising a first acceleration sensor and a second acceleration sensor, wherein the first acceleration sensor is mounted on a first side of the pulley and the second acceleration sensor is mounted on a second side of the pulley;

[0007] A wire breakage detection module, comprising a wire breakage detection sensor and an analog-to-digital converter, wherein the wire breakage detection sensor surrounds the periphery of the wire rope, and the analog-to-digital converter is connected to the wire breakage detection sensor;

[0008] The controller is communicatively connected to the acceleration measurement module and the wire breakage detection module, and is used to control the first acceleration sensor, the second acceleration sensor and the wire breakage detection sensor to collect data.

[0009] According to some embodiments of the present invention, the first acceleration sensor and the second acceleration sensor are both triaxial acceleration sensors, which are used to collect vibration acceleration data of the lifting module and the pulley in the X, Y and Z directions, respectively.

[0010] According to some embodiments of the present invention, the triaxial accelerometer includes a sensor body and a sensor base, with the sensor body disposed on the sensor base.

[0011] According to some embodiments of the present invention, the triaxial accelerometer further includes a sensor signal line, the sensor base is provided with an assembly hole, and the sensor signal line passes through the assembly hole.

[0012] According to some embodiments of the present invention, the broken wire detection sensor includes a Hall element, a magnetic core ring, and an operational amplifier.

[0013] According to some embodiments of the present invention, the magnetic core ring is a circular ring structure, and the magnetic core ring is wrapped around the periphery of the steel wire rope.

[0014] According to some embodiments of the present invention, the controller includes a microprocessor and a power supply module. The microprocessor is used to process the data collected by the first accelerometer and the second accelerometer. The power supply module is powered by either a battery or a 220V power supply.

[0015] According to some embodiments of the present invention, the controller further includes a wireless communication module, which is electrically connected to the microprocessor, and the wireless communication module adopts a Bluetooth or Wi-Fi communication module.

[0016] According to some embodiments of the present invention, the controller further includes an early warning module, which is electrically connected to the microprocessor and is used for audible and visual alarms.

[0017] On the other hand, this utility model embodiment provides a crane lifting mechanism defect detection system, which includes the above-mentioned crane lifting mechanism defect detection device.

[0018] The embodiments of this utility model have at least the following beneficial effects:

[0019] This utility model provides a defect detection device for crane lifting mechanisms, comprising an acceleration measurement module, a wire breakage detection module, and a controller. By integrating a first acceleration sensor, a second acceleration sensor, and a wire breakage detection sensor, real-time monitoring of defects in the pulley grooves and wire ropes of the crane lifting mechanism is achieved. The first and second acceleration sensors synchronously collect vibration acceleration data of the pulleys, and through comparative analysis, determine whether there are defects such as wear or deformation in the pulley grooves. The wire breakage detection sensor utilizes the Hall element principle to monitor changes in the magnetic permeability of the wire rope and converts this into changes in output voltage. Based on a preset threshold, it determines the number and distribution of broken wires in the wire rope. This device can quickly detect defects in the pulley grooves and wire ropes and accurately determine the severity of the defects, improving the safety and reliability of the crane lifting mechanism and providing strong protection for the safe operation of the crane.

[0020] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0021] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0022] Figure 1 This is a block diagram of a defect detection device for a crane lifting mechanism according to an embodiment of the present utility model;

[0023] Figure 2 for Figure 1 The diagram shows the structure of the first acceleration sensor in the defect detection device for the crane lifting mechanism.

[0024] Figure 3 for Figure 1 The diagram shows the structure of the wire breakage detection sensor in the defect detection device for the crane lifting mechanism;

[0025] Figure 4 for Figure 1 The diagram shown illustrates the wireless communication principle of a defect detection device for a crane lifting mechanism.

[0026] Figure 5 This is a block diagram of a defect detection system for a crane lifting mechanism according to an embodiment of the present invention.

[0027] Figure label:

[0028] Acceleration measurement module 100, first acceleration sensor 110, sensor body 111, sensor base 112, sensor signal line 113, mounting hole 114, second acceleration sensor 120, wire breakage detection module 200, wire breakage detection sensor 210, Hall element 211, magnetic core ring 212, operational amplifier 213, analog-to-digital converter 220, controller 300, microprocessor 310, power supply module 320, wireless communication module 330, early warning module 340, display module 350;

[0029] Lifting mechanism 400, pulley 410, wire rope 420, lifting module 430. Detailed Implementation

[0030] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0031] In the description of this utility model, it should be understood that the directional descriptions, such as up, down, front, back, left, right, etc., indicate the directional or positional relationship based on the directional or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0032] In the description of this utility model, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. If "first," "second," etc., are used in the description, they are only for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the sequential relationship of the indicated technical features.

[0033] In the description of this utility model, unless otherwise explicitly defined, the terms "setting", "installing", "connecting" and "connected" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in combination with the specific content of the technical solution.

[0034] The technical solution of this utility model will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0035] Please refer to Figures 1 to 3This embodiment discloses a defect detection device for a crane lifting mechanism, including an acceleration measurement module 100, a wire breakage detection module 200, and a controller 300. The lifting mechanism 400 includes a pulley 410, a wire rope 420, and a lifting module 430. The acceleration measurement module 100 includes a first acceleration sensor 110 and a second acceleration sensor 120. The first acceleration sensor 110 is installed on the first side of the pulley 410, and the second acceleration sensor 120 is installed on the second side of the pulley 410. The wire breakage detection module 200 includes a wire breakage detection sensor 210 and an analog-to-digital converter 220. The wire breakage detection sensor 210 surrounds the wire rope 420, and the analog-to-digital converter 220 is connected to the wire breakage detection sensor 210. The controller 300 is communicatively connected to the acceleration measurement module 100 and the wire breakage detection module 200, and the controller 300 is used to control the first acceleration sensor 110, the second acceleration sensor 120, and the wire breakage detection sensor 210 to collect data. By integrating a first accelerometer 110, a second accelerometer 120, and a broken wire detection sensor 210, real-time monitoring of defects in the pulley 410 groove and wire rope 420 of the crane lifting mechanism is achieved. The first accelerometer 110 and the second accelerometer 120 synchronously collect vibration acceleration data of the pulley 410. Through comparative analysis, the presence of wear, deformation, or other defects in the pulley 410 groove is determined. The broken wire detection sensor 210 utilizes the Hall element principle to monitor changes in the magnetic permeability of the wire rope 420 and converts this into changes in output voltage. Based on a preset threshold, the number and distribution of broken wires in the wire rope 420 are determined. This system can quickly detect defects in the pulley 410 groove and wire rope 420 and accurately determine the severity of these defects, improving the safety and reliability of the crane lifting mechanism and providing strong protection for the safe operation of the crane.

[0036] Please refer to Figure 1 and Figure 2 Both the first accelerometer 110 and the second accelerometer 120 are triaxial accelerometers used to collect vibration acceleration data of the pulley 410 in the X, Y, and Z directions. The first accelerometer 110 and the second accelerometer 120 are respectively installed on both sides of the pulley 410. They monitor the vibration acceleration of the pulley 410 in the X, Y, and Z directions, ensuring good stability of the pulley 410 during operation. The first accelerometer 110 and the second accelerometer 120 work together to achieve precise monitoring of the vibration of the pulley 410 in three-dimensional space. The received vibration acceleration information is converted into electrical signals, which are then analyzed and processed in real time by the controller 300. This effectively prevents abnormal vibrations during crane operation and improves the stability and safety of crane operation.

[0037] Please refer to Figure 2 The triaxial accelerometer includes a sensor body 111 and a sensor base 112, with the sensor body 111 mounted on the sensor base 112. The sensor body 111 detects acceleration signals and converts them into electrical signals for output, while the sensor base 112 provides a stable mounting foundation. The sensor body 111 and base 112 work together to enable the sensor to accurately sense acceleration changes in the X, Y, and Z directions and convert these changes into precise measurement data. When the triaxial accelerometer is subjected to acceleration, the sensitive element inside the sensor body 111 generates corresponding deformation or electrical signal changes based on the acceleration changes. These signals are processed and converted into precise acceleration values, ensuring that the sensor body 111 can stably and accurately sense acceleration changes, thereby achieving comprehensive acceleration monitoring.

[0038] Please refer to Figure 2 The triaxial accelerometer also includes a sensor signal line 113. The sensor base 112 has mounting holes 114 through which the sensor signal line 113 passes. The sensor base 112 provides a platform for mounting and securing the triaxial accelerometer, allowing it to be stably installed in the desired position. The sensor signal line 113 is responsible for transmitting the acceleration information detected by the accelerometer to the controller 300, enabling real-time data transmission and processing. When acceleration occurs, the triaxial accelerometer internally converts it into an electrical signal, which is then transmitted to the controller 300 via the sensor signal line 113, thereby achieving precise monitoring and control of the acceleration.

[0039] Please refer to Figure 3The wire breakage detection sensor 210 includes a Hall element 211, a magnetic core ring 212, and an operational amplifier 213. The magnetic core ring 212 is a circular ring structure that surrounds the steel wire rope 420. The Hall element 18 is open-type. The steel wire rope 420 passes through the magnetic core ring 212, serving as the iron core of the coil in the magnetic core ring 212. When a wire in the steel wire rope 420 is broken, the permeability at the break point decreases, and the inductance of the coil decreases, thereby generating an unbalanced induced electromotive force voltage. The operational amplifier 213 amplifies the voltage value, outputting a changing voltage value. The voltage value is proportional to the number of broken wires, thus determining the number of broken wires in the steel wire rope. The operational amplifier 213 is responsible for amplifying the electrical signal output by the Hall element 211, enabling even very weak signals to be clearly detected. The wire breakage detection sensor 210 is mounted on the wire rope 420 via a magnetic core ring 212. The Hall element 211 detects changes in the magnetic field around the wire rope 420. The magnetic core ring 212 enhances the magnetic field strength, enabling the Hall element 211 to respond more sensitively to changes in the magnetic field. The operational amplifier 213 amplifies these changing signals for subsequent processing and judgment.

[0040] Please refer to Figure 1 The controller 300 includes a microprocessor 310 and a power supply module 320. The microprocessor 310 processes data collected by the first accelerometer 110 and the second accelerometer 120. The power supply module 320 can be powered by either a battery or a 220V power supply. The microprocessor 310 receives and processes the data collected by the first accelerometer 110 and the second accelerometer 120, and detects the device's motion status or provides fault warnings by comparing and analyzing the data. The power supply module 320 provides a stable power supply, supporting both battery power and 220V power supply, ensuring normal operation under different environments and conditions, and enhancing reliability and flexibility.

[0041] Please refer to Figure 1 and Figure 4 The controller 300 also includes a wireless communication module 330, which is electrically connected to the microprocessor 310. The wireless communication module 330 uses Bluetooth or Wi-Fi communication. The microprocessor 310 in the controller 300 is responsible for processing and controlling the overall operation; the wireless communication module 330 conducts reliable data exchange via Bluetooth or Wi-Fi technology. Wireless communication is used between the transmitter and receiver. The transmitter wirelessly transmits the data collected by the sensors to the receiver for processing, and the processing results are displayed on the display module 350. This achieves accurate data acquisition and processing while providing convenient remote control capabilities, improving the overall ease of use and flexibility.

[0042] Please refer to Figure 1The controller 300 also includes a warning module 340, which is electrically connected to the microprocessor 310. The warning module 340 is used for audible and visual alarms. The warning module 340 includes a buzzer and an LED light. If an abnormality or defect is detected during the detection process, the alarm mechanism is triggered to provide audible, visual, or other forms of alarm.

[0043] Please refer to Figure 5 This embodiment also discloses a crane lifting mechanism defect detection system, including the aforementioned crane lifting mechanism defect detection device. The detection system further includes a display module 350, which includes system settings, waveform display, and detection result display.

[0044] During testing, two triaxial accelerometers should be installed on the crane lifting module 430 near the pulley 410. For example, the first accelerometer 110 should be installed on the left bracket of the pulley 410, and the second accelerometer 120 on the right bracket of the pulley 410, ensuring comprehensive capture of the pulley 410's vibration. During installation, ensure the triaxial accelerometers are tightly fitted to the brackets to prevent loosening from affecting data acquisition. Simultaneously, ensure the sensor's installation direction aligns with the preset X, Y, and Z axis directions to ensure data accuracy. The two triaxial accelerometers synchronously acquire vibration acceleration data of the pulley in the X, Y, and Z directions. The acquisition frequency is set to 100 times per second to ensure timely capture of subtle vibration changes in the pulley. After the wire breakage detection sensor 210 is activated, it uses the wire rope 420 as the core of the detection, utilizing the Hall element principle to monitor changes in the wire rope's magnetic permeability. Once a wire breakage is detected in the wire rope 420, this change will be immediately captured by the wire breakage detection sensor 210 and converted into fluctuations in the output voltage. After receiving data from two triaxial accelerometers, the microprocessor 310 begins analysis and processing. By analyzing and comparing the vibration data collected by the two triaxial accelerometers, it searches for abnormal changes in parameters such as frequency and amplitude to determine whether there are wear or deformation defects in the pulley groove. This allows for quick and accurate assessment of pulley 410 groove defects. For the wire rope 420, the microprocessor 310 determines the number and distribution of broken wires based on changes in the output voltage and a preset threshold. The system displays the detection results on the display module 350. The entire detection process is fast and accurate. Once the data processing module detects any abnormality or defect, it immediately triggers an alarm mechanism, alerting the operator and reminding them to promptly inspect and repair the crane. With its compact structure, ease of installation and maintenance, and suitability for various crane models, the system integrates a first acceleration sensor 110, a second acceleration sensor 120, and a broken wire detection sensor 210 to enable real-time monitoring and rapid assessment of defects in the pulley groove of the crane lifting mechanism 410 and the wire rope 420, providing strong assurance for the safe operation of the crane.

[0045] The embodiments of the present utility model have been described in detail above with reference to the accompanying drawings. However, the present utility model is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present utility model.

Claims

1. A defect detection device for a crane lifting mechanism, the lifting mechanism (400) comprising a pulley (410) and a wire rope (420), characterized in that, The detection device includes: An acceleration measurement module (100) includes a first acceleration sensor (110) and a second acceleration sensor (120). The first acceleration sensor (110) is installed on a first side of the pulley (410), and the second acceleration sensor (120) is installed on a second side of the pulley (410). A wire breakage detection module (200) includes a wire breakage detection sensor (210) and an analog-to-digital converter (220). The wire breakage detection sensor (210) is surrounded around the steel wire rope (420), and the analog-to-digital converter (220) is connected to the wire breakage detection sensor (210). The controller (300) is communicatively connected to the acceleration measurement module (100) and the wire breakage detection module (200), respectively. The controller (300) is used to control the first acceleration sensor (110), the second acceleration sensor (120) and the wire breakage detection sensor (210) to collect data.

2. The crane lifting mechanism defect detection device according to claim 1, characterized in that, The first accelerometer (110) and the second accelerometer (120) are both triaxial accelerometers used to collect vibration acceleration data of the pulley (410) in the X, Y and Z directions.

3. The crane lifting mechanism defect detection device according to claim 2, characterized in that, The triaxial accelerometer includes a sensor body (111) and a sensor base (112), with the sensor body (111) mounted on the sensor base (112).

4. The crane lifting mechanism defect detection device according to claim 3, characterized in that, The triaxial accelerometer also includes a sensor signal line (113), and the sensor base (112) is provided with an assembly hole (114), through which the sensor signal line (113) passes.

5. The crane lifting mechanism defect detection device according to claim 1, characterized in that, The broken wire detection sensor (210) includes a Hall element (211), a magnetic core ring (212), and an operational amplifier (213).

6. The crane lifting mechanism defect detection device according to claim 5, characterized in that, The magnetic core ring (212) is a circular ring structure, and the magnetic core ring (212) surrounds the outer periphery of the steel wire rope (420).

7. The crane lifting mechanism defect detection device according to claim 1, characterized in that, The controller (300) includes a microprocessor (310) and a power module (320). The microprocessor (310) is used to process the data collected by the first accelerometer (110) and the second accelerometer (120). The power supply module (320) is powered by a battery or by a 220V power supply.

8. The crane lifting mechanism defect detection device according to claim 7, characterized in that, The controller (300) further includes a wireless communication module (330), which is electrically connected to the microprocessor (310). The wireless communication module (330) is a Bluetooth or Wi-Fi communication module.

9. The crane lifting mechanism defect detection device according to claim 7, characterized in that, The controller (300) further includes an early warning module (340), which is electrically connected to the microprocessor (310) and is used for audible and visual alarms.

10. A defect detection system for a crane lifting mechanism, characterized in that, The crane lifting mechanism defect detection system includes the crane lifting mechanism defect detection device as described in any one of claims 1 to 9.

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