Real-time monitoring system for band-type brake of nodular cast iron pipeline crane

Abstract

The utility model discloses a nodular cast iron pipeline crane band-type brake real-time monitoring system, which comprises a data storage part, a data acquisition part, a data processing part and a power supply part, the data acquisition part comprises a voltage sensor, a current sensor, a band-type brake state feedback device and a camera, and a band-type brake controller is connected with a band-type brake through a control circuit. The voltage sensor and the current sensor are arranged on the control circuit, the band-type brake state feedback device is connected with the band-type brake, the camera is arranged corresponding to the band-type brake, the voltage sensor, the current sensor and the camera are all connected with the data storage part, and the voltage sensor, the current sensor and the band-type brake state feedback device are all connected with the data processing part. The power supply part is connected with the data storage part and the data acquisition part; the device is complete in structure, good in integration level, high in real-time performance, reliable in work, and capable of monitoring the working state of the band-type brake in real time in an all-weather mode, finding tiny abnormity existing in the working process of the band-type brake in time, and greatly improving the safety in the molten iron casting process.

Description

Technical Field

[0001] This utility model relates to the field of pipeline production technology, specifically to a real-time monitoring system for the brake of a ductile iron pipeline crane. Background Technology

[0002] As a type of molten iron casting product, ductile iron pipes require cranes to transfer and pour molten iron ladles during their production process, and then, in conjunction with other equipment, to cast the molten iron into the products needed by the factory.

[0003] Molten iron can only be stored in a specially designed ladle. Due to its extremely high temperature, if it is accidentally spilled on the ground, it can rapidly evaporate the moisture on the ground, causing a violent explosion, which is extremely dangerous. Therefore, there is a great risk during its transfer and dumping. For this reason, cranes are equipped with control devices such as brakes to ensure the smooth and safe transfer and dumping of molten iron.

[0004] The crane's main hook is used for vertically lifting molten iron ladles. It is equipped with a dedicated safety brake device, the main body of which is a large metal disc-shaped brake disc connected to the main hook drive mechanism. On each side of the main hook, there is an electromagnetically driven clamp-shaped brake disc, powered by a dedicated brake controller. When the brake controller receives an activation signal, it outputs DC power, generating electromagnetic force within the brake disc. This force drives the brake plates on the brake disc, causing them to clamp tightly onto the disc-shaped brake disc and preventing the main hook mechanism from moving.

[0005] In actual use, due to the deterioration of the performance of the brake controller, damage to the output line of the brake controller, etc., the brake disc may not move properly and may not lock the brake disc tightly. When the friction generated by the brake pads on the brake disc is less than the weight of the molten iron ladle, the molten iron ladle will slip and produce a "hook slippage" phenomenon. During the descent, due to the excessive height, it may fall directly or overturn, resulting in a serious production accident.

[0006] In view of the above-mentioned defects, the creator of this utility model has finally obtained this utility model after a long period of research and practice. Utility Model Content

[0007] To address the aforementioned technical deficiencies, this utility model provides a real-time monitoring system for the brake of a ductile iron pipe crane, comprising a data storage unit, a data acquisition unit, a data processing unit, and a power supply unit. The data acquisition unit includes a voltage sensor, a current sensor, a brake status feedback device, and a camera. The brake controller is connected to the brake via a control circuit. The voltage sensor and the current sensor are mounted on the control circuit. The brake status feedback device is connected to the brake. The camera is positioned corresponding to the brake. The voltage sensor, the current sensor, and the camera are all connected to the data storage unit. The voltage sensor, the current sensor, and the brake status feedback device are all connected to the data processing unit. The power supply unit is connected to both the data storage unit and the data acquisition unit.

[0008] Preferably, the voltage sensor is connected to the data interface module via a voltage signal converter, the current sensor is connected to the data interface module via a current signal converter, and the data interface module is connected to both the data storage unit and the data processing unit.

[0009] Preferably, the brake status feedback device is a stroke sensor, which is installed on the brake to detect the movement stroke of the brake pads on the brake.

[0010] Preferably, the data storage unit includes a digital display unit, a video monitoring unit, and a data storage unit. The digital display unit, the video monitoring unit, and the data storage unit are all connected to the data interface module. The camera is connected to the video monitoring unit through the data interface module. The video monitoring unit is used to store video information collected by the camera. The data storage unit is used to store voltage information collected by the voltage sensor and current information collected by the current sensor. The digital display unit is used to display the voltage information collected by the voltage sensor and the current information collected by the current sensor in real time.

[0011] Preferably, the digital display unit is also connected to the video monitoring unit and the data storage unit through the data interface module.

[0012] Preferably, the data storage unit further includes an NTP time synchronization server, which is connected to both the video surveillance unit and the data storage unit, and the NTP time synchronization server is wirelessly connected to a satellite.

[0013] Preferably, the data processing unit includes a PLC module, which is connected to both the data interface module and the brake status feedback device. The PLC module receives voltage information collected by the voltage sensor, current information collected by the current sensor, and brake status information from the brake status feedback device, and performs data processing and judgment.

[0014] Preferably, the data processing unit further includes an alarm, and the PLC module is connected to the alarm.

[0015] Preferably, the PLC module is connected to the brake and the crane.

[0016] Preferably, the power supply unit includes a power module, a protection module, an isolation transformer, a conversion module, and a voltage regulator module. The power module is connected in sequence through the protection module, the isolation transformer, the conversion module, and the voltage regulator module, and is also connected to the digital display unit, the data storage unit, the data interface module, the voltage signal converter, and the current signal converter through the voltage regulator module.

[0017] Compared with the prior art, the advantages of this utility model are as follows: This utility model has a perfect structure, good integration, high real-time performance, and reliable operation. It can monitor the working status of the brake in real time around the clock, promptly detect minor abnormalities in the operation of the brake, greatly improve the safety of the molten iron casting process, and provide intuitive and reliable data and visual support for professional technicians in the subsequent fault investigation and judgment, reducing the difficulty of troubleshooting and improving maintenance efficiency. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the real-time monitoring system for the brake of the ductile iron pipe crane.

[0019] Figure 2 This is a schematic diagram of the connection structure of the power supply unit.

[0020] The numbers in the diagram represent:

[0021] 1-Current sensor; 2-Voltage sensor. Detailed Implementation

[0022] The above-mentioned and other technical features and advantages of this utility model will be described in more detail below with reference to the accompanying drawings.

[0023] Example 1

[0024] like Figure 1 As shown, Figure 1 This is a schematic diagram of the structure of the real-time monitoring system for the brake of the ductile iron pipe crane.

[0025] The real-time monitoring system for the brake of a ductile iron pipe crane, as described in this utility model, includes a data storage unit, a data acquisition unit, and a data processing unit. The data acquisition unit includes a voltage sensor 2, a current sensor 1, a brake status feedback device, and a camera. The brake controller is connected to the brake via a control circuit. The voltage sensor 2 and the current sensor 1 are mounted on the control circuit to collect real-time voltage and current data. The brake status feedback device is connected to the brake to collect the brake's clamping state in real time. The camera is positioned corresponding to the brake to collect the brake's operating state. The voltage sensor 2, the current sensor 1, and the camera are all connected to the data storage unit, which stores the voltage information collected by the voltage sensor 2, the current information collected by the current sensor 1, and the video information collected by the camera. The voltage sensor 2, the current sensor 1, and the brake status feedback device are all connected to the data processing unit, which provides early warnings based on the voltage information collected by the voltage sensor 2, the current information collected by the current sensor 1, and the brake status information from the brake status feedback device.

[0026] Specifically, the voltage sensor 2 is connected to the data interface module via a voltage signal converter, and the current sensor 1 is connected to the data interface module via a current signal converter. The data interface module is also connected to the data storage unit and the data processing unit, thereby enabling the transmission of the voltage information and the current information with the data storage unit and the data processing unit.

[0027] Generally, the brake status feedback device is a stroke sensor, which is installed on the brake to detect the movement stroke of the brake pads.

[0028] The data storage unit includes a digital display unit, a video monitoring unit, and a data storage unit. The digital display unit, the video monitoring unit, and the data storage unit are all connected to the data interface module. The camera is connected to the video monitoring unit through the data interface module. The video monitoring unit is used to store video information collected by the camera. The data storage unit is used to store voltage information collected by the voltage sensor 2 and current information collected by the current sensor 1. The digital display unit is used to display the voltage information collected by the voltage sensor 2 and the current information collected by the current sensor 1 in real time.

[0029] Preferably, the digital display unit is also connected to the video monitoring unit and the data storage unit through the data interface module, so that the operator can retrieve the voltage information, the current information and the video information corresponding to a certain time period for troubleshooting, etc.

[0030] The data storage unit also includes an NTP time server, which is connected to both the video monitoring unit and the data storage unit. The NTP time server is wirelessly connected to a satellite and transmits the received satellite signals to the video monitoring unit and the data storage unit at set time intervals in real time, ensuring absolute time synchronization of the data of the two units, which facilitates subsequent retrieval and viewing of the voltage information, current information and video information for the corresponding time period.

[0031] The data processing unit includes a PLC module, which is connected to the data interface module and the brake status feedback device. The PLC module receives voltage information collected by the voltage sensor 2, current information collected by the current sensor 1, and brake status information from the brake status feedback device, and performs data processing and judgment.

[0032] Preferably, the data processing unit further includes an alarm, and the PLC module is connected to the alarm. When the PLC module determines that a fault has occurred, the PLC module issues an early warning through the alarm.

[0033] Generally, the PLC module is connected to the brake and the crane. When the PLC module determines that a serious fault has occurred, it immediately outputs a stop signal and locks the brake, cutting off further movement of the crane and waiting for professional maintenance personnel to intervene for inspection and investigation.

[0034] This utility model has a perfect structure, good integration, high real-time performance, and reliable operation. It can monitor the working status of the brake in real time around the clock, promptly detect minor abnormalities in the operation of the brake, greatly improve the safety of the molten iron casting process, and provide intuitive and reliable data and visual support for professional technicians in the subsequent fault investigation and judgment, reducing the difficulty of troubleshooting and improving maintenance efficiency.

[0035] Example 2

[0036] To ensure the reliable operation of the monitoring system, the system must have high precision. Therefore, an independent power supply system was designed for each of the main components of the system.

[0037] The real-time monitoring system for the brake of a ductile iron pipe crane according to this utility model also includes a power supply unit, which includes a power module, a protection module, an isolation transformer, a conversion module, and a voltage stabilizing module. The power module is connected in sequence through the protection module, the isolation transformer, the conversion module, and the voltage stabilizing module, and is also connected to the digital display unit, the data storage unit, the data interface module, the voltage signal converter, and the current signal converter through the voltage stabilizing module.

[0038] like Figure 2As shown, Figure 2 This is a schematic diagram of the connection structure of the power supply unit. The power supply is taken from the crane power supply system. The protection module has functions such as overload protection, short circuit protection, and grounding protection, and also has considerable anti-harmonic interference capability. The isolation transformer adjusts the power supply voltage to the voltage range usable by the monitoring system, and then the AC to DC conversion module regulates the AC power to the nominal DC power supply of each component. The voltage stabilization module further improves the power supply quality, preventing accidents such as voltage spikes and power failures caused by interference or short-term unexpected power outages, protecting the stable operation of each component and extending its electrical life.

[0039] Example 3

[0040] A Hall voltage and current detection sensor, namely the voltage sensor 2 and the current sensor 1, are installed on the control circuit of the brake controller output to the brakes on both sides. The output signals of the Hall voltage and current detection sensors are converted by the voltage signal converter and the current signal converter, respectively, and then sent to the digital display unit, the video monitoring unit, the data storage unit and the PLC module installed in the cab through the data interface module.

[0041] The digital display unit displays the voltage and current values ​​of the current control circuit in real time, and the video monitoring unit displays the operating status of the brake disc in real time. The video monitoring unit has built-in video saving and playback functions. The data storage unit is used to archive and save the voltage and current data of the voltage sensor 2 and the current sensor 1. The PLC module calculates and judges the received voltage and current data and the brake status fed back by the brake status feedback device according to a pre-programmed algorithm. When the judgment result is a minor abnormality, the PLC module drives the alarm to issue an audible and visual alarm to remind the driver to pay attention and intervene manually if necessary. When the judgment result is a serious abnormality, a stop signal is immediately output, and the brake is locked to cut off further movement of the crane, waiting for professional maintenance personnel to intervene for inspection and investigation.

[0042] Once professional maintenance personnel arrive, they can directly retrieve the brake voltage and current data archived in the data storage unit, and combine it with the real-time footage stored in the video monitoring unit at the same time to accurately determine the direct cause of the abnormal brake action and quickly eliminate system faults.

[0043] The specific usage method of this utility model includes: the PLC module receives the real-time voltage value collected by the voltage sensor 2, the real-time current value collected by the current sensor 1, and the real-time brake status data of the brake status feedback device, and performs data processing and judgment. The judged status includes normal status, controller fault status, control circuit fault status, and brake fault status.

[0044] Specifically, the PLC module is equipped with normal voltage thresholds and normal current thresholds.

[0045] When the real-time voltage value and the real-time current value are stable, and the real-time voltage value is higher than the normal voltage threshold and the real-time current value is higher than the normal current threshold, the brake status feedback device will indicate that the brake is operating normally, and the system is in the normal state.

[0046] When the real-time voltage value is lower than the normal voltage threshold, and the real-time current value decreases as the real-time voltage value decreases, the controller is in a fault state. In this case, due to the deterioration of the brake controller, the current will also decrease as the output voltage decreases because the resistance remains constant. When the controller is in a fault state, the PLC module will issue a warning through the alarm, and manual intervention will be provided if necessary.

[0047] When the real-time voltage value is higher than the normal voltage threshold and the value is stable, but the real-time current value decreases, the control circuit is in a fault state. At this time, due to possible poor contact in the control circuit, the resistance of the control circuit increases, resulting in a normal voltage but a lower current. When the real-time current value is still higher than the normal current threshold, the brake is still in a normally operable power supply state and needs to be repaired in time. When the circuit continues to deteriorate and the real-time current value drops below the normal current threshold, the brake cannot operate and the system shuts down.

[0048] When the real-time voltage and real-time current values ​​are stable, and the real-time voltage value is higher than the normal voltage threshold and the real-time current value is higher than the normal current threshold, but the brake status feedback device indicates that the brake cannot operate, then the brake is in a fault state. In this case, foreign objects may have entered the brake disc; the voltage and current may be normal, but there is no feedback signal. When in the brake fault state, the PLC module immediately outputs a stop signal and simultaneously engages the brake, cutting off further crane operation and awaiting intervention and investigation by professional maintenance personnel.

[0049] The PLC module can quickly and accurately identify the type of fault, thereby reducing the difficulty of troubleshooting and improving maintenance efficiency.

[0050] The above description is merely a preferred embodiment of the present utility model and is illustrative rather than restrictive. Those skilled in the art will understand that many changes, modifications, and even equivalents can be made within the spirit and scope defined by the claims of the present utility model, all of which will fall within the protection scope of the present utility model.

Claims

1. A ductile cast iron pipe crane brake real-time monitoring system, characterized in that, Including data storage unit, data acquisition unit, data processing unit and power supply unit, the data acquisition unit includes voltage sensor, current sensor, brake state feedback device and camera, brake controller through control circuit and brake connection, the voltage sensor and the current sensor are arranged on the control circuit, the brake state feedback device is connected with the brake, the camera is correspondingly arranged on the brake, the voltage sensor, the current sensor and the camera are connected with the data storage unit, the voltage sensor, the current sensor and the brake state feedback device are connected with the data processing unit, the power supply unit is connected with the data storage unit, the data acquisition unit.

2. The ductile iron pipe and bucket brake real-time monitoring system of claim 1, wherein, The voltage sensor is connected with the data interface module through the voltage signal converter, the current sensor is connected with the data interface module through the current signal converter, and the data interface module is connected with the data storage unit and the data processing unit.

3. The ductile iron pipe and bucket brake real-time monitoring system of claim 1, wherein, The brake state feedback device is a travel sensor, which is arranged on the brake to detect the movement stroke of the brake piece on the brake.

4. The ductile iron pipe and bucket brake real-time monitoring system of claim 2, wherein, The data storage unit includes digital display unit, video monitoring unit and data storage unit, the digital display unit, the video monitoring unit and the data storage unit are connected with the data interface module, the camera is connected with the video monitoring unit through the data interface module, the video monitoring unit is used to store the video information collected by the camera, the data storage unit is used to store the voltage information collected by the voltage sensor and the current information collected by the current sensor, and the digital display unit is used to display the voltage information collected by the voltage sensor and the current information collected by the current sensor in real time.

5. The ductile iron pipe and bucket brake real-time monitoring system of claim 4, wherein, The digital display unit is also connected with the video monitoring unit and the data storage unit through the data interface module.

6. The ductile iron pipe and bucket brake real-time monitoring system of claim 4, wherein, The data storage unit further comprises an NTP time server, which is connected with the video monitoring unit and the data storage unit simultaneously, and the NTP time server is wirelessly connected with the satellite.

7. The ductile iron pipe and bucket brake real-time monitoring system of claim 4, wherein, The data processing unit includes a PLC module, which is connected with the data interface module and the brake state feedback device, receives the voltage information collected by the voltage sensor, the current information collected by the current sensor and the brake state information of the brake state feedback device, and performs data processing and judgment.

8. The ductile iron pipe and bucket brake real-time monitoring system of claim 7, wherein, The data processing unit further comprises an alarm, and the PLC module is connected with the alarm.

9. The ductile iron pipe and bucket brake real-time monitoring system of claim 8, wherein, The PLC module is connected with the brake and the crane.

10. The ductile iron pipe and bucket brake real-time monitoring system of claim 4, wherein, The power supply unit includes a power supply module, a protection module, an isolation transformer, a conversion module and a voltage stabilizing module, the power supply module is sequentially connected through the protection module, the isolation transformer, the conversion module and the voltage stabilizing module, and is connected with the digital display unit, the data storage unit, the data interface module, the voltage signal converter and the current signal converter through the voltage stabilizing module.

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