Underground monorail crane wireless sensor monitoring network and monitoring method therefor

Abstract

Disclosed in the present invention is an underground monorail crane wireless sensor monitoring network, comprising a coordinator aggregation node, a data display and processing device, and a plurality of brake block monitoring nodes, pull rod stress monitoring nodes, compartment vibration monitoring nodes and routing relay nodes; the brake block monitoring nodes, the pull rod stress monitoring nodes and the compartment vibration monitoring nodes are respectively in communication connection with the routing relay nodes by means of universal communication control modules; the routing relay nodes are in communication connection with the coordinator aggregation node by means of universal communication control modules; the coordinator aggregation node is in communication connection with the data display and processing device by means of a universal communication control module. In the present invention, the nodes are distributed at all positions of the body of a locomotive for monitoring the braking, vibration and pull rod states of a monorail crane, so as to compensate for monitoring defects of electrical control systems, and node monitoring data and locomotive electrical control system data are uploaded to a locomotive control room by means of wireless communication base stations in mine roadways, thus achieving real-time monitoring of the operating state of monorail cranes.

Description

A wireless sensor monitoring network and monitoring method for underground monorail crane Technical Field

[0001] The present invention relates to the field of wireless sensor monitoring networks, and in particular to an underground monorail crane wireless sensor monitoring network and a monitoring method thereof. Background Art

[0002] The degree of modernization of auxiliary transport mechanization is crucial to achieving efficient coal mine production. Traditional auxiliary transport methods, such as overhead trolley locomotives, battery locomotives, and winches, are often highly complex, involve numerous transport links, and result in low transport efficiency. Monorail crane locomotives address the shortcomings of overhead trolley locomotives and battery locomotives, lacking the gradeability to operate. This not only improves transport efficiency but also reduces labor costs and the occurrence of transport accidents. Due to these numerous advantages, monorail crane locomotives have been increasingly adopted by major coal mines.

[0003] Currently, monorail crane monitoring systems are primarily installed on the locomotive's front section, monitoring the operating status of the locomotive's equipment and forming a crucial component of the locomotive's electronic control system. When a monorail crane's electrical or hydraulic equipment fails, affecting the locomotive's stable operation, the electronic control system can often detect and resolve the issue. However, current monitoring of monorail cranes is limited to the electronic control instruments in the locomotive cab, lacking monitoring of the locomotive's mechanical structure. The locomotive's mechanical components currently rely on regular manual inspections and maintenance. The Inoue locomotive monitoring room's understanding of the locomotive is limited to the location information from the positioning system. Unexpected events require the driver to proactively report and provide feedback. Existing monitoring is fragmented and lacks systematic, real-time, proactive monitoring.

[0004] Summary of the Invention

[0005] Purpose of the invention: In response to the above problems, the purpose of the present invention is to provide an underground monorail crane wireless sensor monitoring network and a monitoring method thereof, establish a monorail crane operation status monitoring system, arrange nodes at various locations on the locomotive body, monitor the braking, vibration, and pull rod status of the monorail crane, make up for the monitoring loopholes of the electrical control system, upload the node monitoring data and the locomotive electronic control system data to the locomotive control room through the mine tunnel wireless communication base station, realize real-time monitoring of the monorail crane operation status, and according to the linear layout characteristics of the monitoring nodes, use a non-uniform deployment strategy to balance the energy consumption of routing nodes, extend the network life, and ensure the safe and efficient operation of the entire transportation system.

[0006] Technical solution: One aspect of the present invention provides an underground monorail crane wireless sensor monitoring network, including a coordinator aggregation node, a data display and processing device, and a plurality of brake block monitoring nodes, a tie rod stress monitoring node, a carriage vibration monitoring node, and a routing relay node;

[0007] The brake block monitoring node, the tie rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through a universal communication control module, the routing relay node is connected to the coordinator aggregation node through a universal communication control module, and the coordinator aggregation node is connected to the data display and processing equipment through a universal communication control module;

[0008] Brake block monitoring nodes are distributed and installed on the monorail crane braking device to collect brake block wear and temperature data;

[0009] The tie rod stress monitoring node is installed on the monorail tie rod to monitor the tie rod stress condition in real time;

[0010] The carriage vibration monitoring node is installed on the monorail crane carriage to monitor the three-axis vibration acceleration and three-axis roll angle of the carriage in real time;

[0011] The routing relay node is installed on the body of the monorail crane and is used to collect and forward data from nodes within the cluster;

[0012] The coordinator aggregation node is installed in the monorail crane cab and is used to collect data from all nodes in the monitoring network and locomotive electronic control parameters;

[0013] The data display and processing equipment is set up in the mine tunnel locomotive dispatching room and receives all node data and locomotive electronic control parameters through the mine Ethernet ring network.

[0014] Furthermore, the brake block monitoring node includes a brake sensor FPC board, a brake information processing module, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a brake information processing module housing;

[0015] The brake sensor FPC board is connected to the brake information processing module, the brake information processing module is connected to the communication control module, and the communication control module is powered by a universal power supply module. The brake information processing module is installed in the brake information processing module housing, the communication control module is installed in the universal node housing, and the universal power supply module is installed in the universal power supply housing. The universal node housing, the universal power supply housing and the brake information processing module housing are adsorbed on the monorail crane body.

[0016] Furthermore, the tie rod stress monitoring node includes a stress information processing module, a full-bridge strain gauge, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing, and a stress information processing module housing;

[0017] The full-bridge strain gauge is connected to the stress information processing module, the stress information processing module is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the full-bridge strain gauge is pasted on the horizontal direction of the outer end surface of the monorail crane pull rod earring, the stress information processing module is installed in the stress information processing module shell, the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell. The universal node shell, the universal power supply shell and the stress information processing module shell are adsorbed on the monorail crane body.

[0018] Furthermore, the carriage vibration monitoring node includes a universal communication control module, an acceleration sensor, a universal power supply module, a universal node housing, and a universal power supply housing;

[0019] The acceleration sensor is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell, and the universal node shell and the universal power supply shell are adsorbed on the monorail crane body.

[0020] Furthermore, the data display and processing device includes a data display and storage module and a data analysis and processing module, wherein the data display and storage module includes a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module and a display storage and data transmission module; the data analysis and processing module includes an analysis and processing data transmission module, a mathematical model data processing module and a deep learning data processing module;

[0021] The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module. The data storage module stores the received data. The data sending module issues instructions to the monitoring node through the TCP communication module. The data receiving module displays the received raw data frames. The data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the data analysis and processing module, and the display storage and data transmission module transmits data to the data analysis and processing module.

[0022] The data analysis and processing module analyzes and processes the received data, imports the mathematical model data processing module and the deep learning data processing module. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability of the monorail crane in the complex frequency domain based on the vibration signals of each carriage of the monorail crane. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the operating status of the monorail crane, including the locomotive health status, operating status and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module.

[0023] Furthermore, the brake sensor FPC board includes copper wire cables, a temperature sensor and an FPC connector. The spacing between the copper wire cables is determined according to the required brake monitoring accuracy, and the number of copper wire cables is determined by the thickness of the wear area of ​​the brake block. The inner circle of the brake sensor FPC board fits the outer edge of the friction end face of the brake block; the temperature sensor is installed in the non-wear area of ​​the brake block on the brake sensor FPC board, in a horizontal position in the forward direction of the brake block side surface, to monitor the maximum temperature of the brake block side surface.

[0024] Furthermore, the braking information processing module includes a voltage-dividing chip resistor and multiple parallel chip resistors. Each parallel chip resistor is connected to a circuit of copper wire wiring to form multiple parallel loops. The general communication control module collects the total voltage and temperature sensor data of the parallel resistor circuit and uploads it. The data display processing equipment determines the amount of wear based on the collected voltage value.

[0025] Furthermore, the full-bridge strain gauge is pasted on the horizontal direction of the outer end face of the pull rod earring. It is the maximum normal stress component of the outer end face of the pull rod earring obtained by finite element analysis. After amplification and filtering by the stress information processing module, the full-bridge strain gauge output voltage signal is between 0-3.3V. The general communication control module collects the voltage signal and uploads it.

[0026] Furthermore, routing relay nodes are deployed on the monorail crane body in a non-uniform spacing manner, and each routing relay node collects and uploads the data of the monitoring sensor nodes.

[0027] Another aspect of the present invention provides a method for monitoring an underground monorail crane using wireless sensors, comprising the following steps:

[0028] Step 1: Create a wireless sensor network using the coordinator sink node;

[0029] Step 2: Use the brake monitoring node to collect brake shoe wear and temperature data, use the tie rod stress monitoring node to collect the horizontal normal stress of the outer end face of the tie rod earring, and use the car vibration monitoring node to collect the three-axis vibration acceleration and three-axis roll angle of the car;

[0030] Step 3: Use the routing relay node to collect the data of nearby monitoring nodes and upload it to the routing relay node;

[0031] Step 4: Use the coordinator aggregation node to collect Zigbee data from all nodes and collect sensor data from the monorail crane electric control system through the USB interface. Upload the data to the WiFi base stations installed at intervals on the walls of the mine tunnels via WiFi. The WiFi base stations are connected to the mine Ethernet ring network.

[0032] Step 5: The data display and processing device receives the monitoring network data through the mine Ethernet ring network, including:

[0033] The data display and storage module classifies and locates the data frames collected by the node, including brake pad temperature, wear, rod stress, car vibration acceleration, roll angle, and electronic control system sensors, and displays and stores them in real time, generating alarms based on pre-set thresholds.

[0034] The mathematical model data processing module of the data analysis and processing module evaluates the locomotive's operating stability based on the Sperling index in the complex frequency domain of vibration acceleration and roll angle. The deep learning data processing module of the data analysis and processing module determines the locomotive's operating status and extracts features based on the temperature and wear of each brake block, the stress data of each tie rod, the triaxial acceleration and triaxial roll angle data of each carriage, and the sensor data of the locomotive's electronic control system, corresponding to the monorail crane's operating status.

[0035] The deep learning data processing module analyzes the structural abnormalities of the monorail crane track based on stress and vibration data, and makes track status judgments and early warnings for track misalignment. At the same time, based on the monitoring network data and the sensor data parameters of the monorail crane's electronic control system, it extracts features of common operating faults of the monorail crane, and judges and issues early warnings on the health status of the monorail crane based on the monitoring parameters.

[0036] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:

[0037] The present invention is easy to install and maintain, safe and reliable, and has low cost. It will not cause damage to the monorail crane locomotive and will not affect the normal operation of the monorail crane. The node power supply adopts rechargeable lithium batteries, which are reusable and environmentally friendly. The present invention improves the loopholes in the monorail crane's electronic control monitoring system, and performs supplementary monitoring on brakes, pull rods, and vibrations that are not easy to monitor in the hydraulic electronic control system. The present invention uses FPC cables to detect the wear of the monorail crane's brake blocks. The detection method is novel, less sensitive to environmental factors, and reliable. The detection accuracy can be changed according to the spacing between the copper wire conductors, and the brake block thickness and temperature can be monitored in real time even when the monorail crane is running. The present invention monitors the pull rod stress. The pull rod is the main load-bearing component for the operating power of each section of the monorail crane. It is proposed to monitor the horizontal normal stress of the outer end face of the pull rod earring, which is a special point of the pull rod stress distribution and the stress size can effectively reflect the change in earring wear. The present invention monitors the vibration of the monorail crane car. Vibration is an important evaluation index of rail transportation equipment. It is proposed to make up for the car monitoring loopholes from the aspects of three-axis vibration acceleration and three-axis roll angle. The Ming communication control system adopts Zigbee chip as the core processor, which can accurately realize data collection and sensor network data transmission, is easy to network, and can increase the number of monitoring nodes according to the length and structure of the monorail crane; the coordinator aggregation node of the present invention adopts WIFI module to upload data, and uploads it to the locomotive monitoring room in real time according to the wireless communication base station installed in the mine tunnel, without adding additional base station equipment; the data display storage program of the present invention receives sensor network data frames from TCP, judges the data frame category and actual node position, and the user can observe in real time. The data display is intuitive and clear, there is a threshold alarm, and historical data storage is retained; the present invention monitors the overall pull rod stress and car vibration of the monorail crane locomotive in real time, and can achieve real-time monitoring and alarm for major transportation accidents that may occur during operation, such as falling off the track, running away, collision, etc.; the present invention can analyze and judge various operating states, health states, and track states of the monorail crane, and calculate the Sperling index for locomotive operation evaluation based on the car vibration acceleration to judge its operating stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] FIG1 is an overall schematic diagram of the present invention;

[0039] FIG2 is a schematic diagram of the structure of the coordinator convergence node of the present invention;

[0040] FIG3 is a structural diagram of a universal node housing according to the present invention;

[0041] FIG4 is a schematic diagram of the contact structure between the brake pad and the track of the present invention;

[0042] FIG5 is a schematic diagram of a brake monitoring node PCB according to the present invention;

[0043] FIG6 is a structural diagram of the housing of the brake information processing module of the present invention;

[0044] FIG7 is a structural diagram of a universal power supply housing of the present invention;

[0045] FIG8 is a schematic diagram of the installation of a brake sensor module according to the present invention;

[0046] FIG9 is a schematic diagram of a PCB for a tie rod stress monitoring node according to the present invention;

[0047] FIG10 is a structural diagram of the housing of the tie rod stress information processing module of the present invention;

[0048] FIG11 is a schematic diagram of the installation of the pull rod and full-bridge strain gauge of the present invention;

[0049] FIG12 is a schematic diagram of a car vibration monitoring node according to the present invention;

[0050] FIG13 is a finite element analysis diagram of the contact temperature between the brake pad and the track according to the present invention;

[0051] FIG14 is a finite element analysis diagram of the contact wear between the brake pad and the track of the present invention;

[0052] FIG15 is a finite element analysis diagram of the stress of the pull rod earring of the present invention;

[0053] FIG16 is a flowchart of the workflow of the present invention.

[0054] In the figure: 1. Monorail crane track; 2. Monorail crane cab; 3. Coordinator aggregation node; 4. Monorail crane pull rod; 5. Pull rod stress monitoring node; 6. Monorail crane braking device; 7. Braking monitoring node; 8. Monorail crane carriage; 9. Carriage vibration monitoring node; 10. Routing relay node; 11. Data transmission and processing equipment; 12. General communication control module; 13. Reset module; 14. WIFI interface; 15. Braking monitoring interface; 16. Stress monitoring interface; 17. Voltage conversion module; 18. Power supply interface; 19. Power switch; 20. USB interface; 21. Serial communication module; 22. Vibration monitoring interface; 23. JTAG interface; 24. Zigbee chip; 2 5. Universal node housing; 26. Brake block; 27. Braking information processing module; 28. Braking information processing connector; 29. ​​Parallel chip resistor; 30. Braking information processing FPC connector; 31. Braking sensor FPC board; 32. Temperature sensor; 33. FPC copper wire cable; 34. Braking sensor FPC connector; 35. Braking information processing module housing; 36. Universal power supply housing; 37. Full-bridge strain gauge; 38. Monorail suspension rod; 39. Monorail suspension rod earring; 40. Strain information processing module; 41. Stress information processing connector; 42. Low-pass filter module; 43. Full-bridge strain gauge connector; 44. Voltage amplification module; 45. Stress information processing module housing. DETAILED DESCRIPTION

[0055] In order to make the purpose, technical solutions and advantages of this application more clear, this application is further described in detail below with reference to the accompanying drawings and embodiments.

[0056] Example 1

[0057] FIG1 is a schematic diagram of the structure of a wireless sensor monitoring network for an underground monorail crane according to this embodiment, comprising a coordinator aggregation node 3, a data processing device 11, and multiple brake block monitoring nodes 7, a tie rod stress monitoring node 5, a carriage vibration monitoring node 9, and a routing relay node 10;

[0058] The brake block monitoring node, the tie rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through a universal communication control module, the routing relay node is connected to the coordinator aggregation node through a universal communication control module, and the coordinator aggregation node is connected to the data display and processing equipment through a universal communication control module;

[0059] Brake block monitoring nodes are distributed and installed on the monorail crane braking device to collect brake block wear and temperature data;

[0060] The tie rod stress monitoring node is installed on the monorail tie rod to monitor the tie rod stress condition in real time;

[0061] The carriage vibration monitoring node is installed on the monorail crane carriage to monitor the three-axis vibration acceleration and three-axis roll angle of the carriage in real time;

[0062] The routing relay node is installed on the body of the monorail crane and is used to collect and forward data from nodes within the cluster;

[0063] The coordinator aggregation node is installed in the monorail crane cab and is used to collect data from all nodes in the monitoring network and locomotive electronic control parameters;

[0064] The data display and processing equipment is set up in the mine tunnel locomotive dispatching room and receives all node data and locomotive electronic control parameters through the mine Ethernet ring network.

[0065] As shown in Figure 2, the coordinator aggregation node 3 includes a general communication control module 12, a WIFI module, and a general node housing 25. The general communication control module 12 includes a Zigbee chip 24, a voltage conversion module 17, a serial communication module 21, a reset module 13, a JTAG interface 23, a USB interface 20, a power switch 19, a power interface 18, a stress monitoring interface 16, a brake monitoring interface 15, a WIFI interface 14, and a vibration monitoring interface 22. The voltage conversion module 17 includes a 5V voltage conversion chip and a 3.3V voltage conversion chip. The serial communication module 21 includes a serial-to-USB chip and a chip resistor. The reset module 13 includes a touch switch, a chip resistor, and a chip capacitor. The WIFI interface 14 is connected to the WIFI module, and the power interface 18 is connected to a 7.4V lithium battery. The universal communication control module 12 and the WIFI module are installed in the universal node shell 25. The structural schematic diagram of the universal node shell 25 is shown in Figure 3. The universal node shell 25 is adsorbed in the monorail crane cab 2 by a magnet. The universal communication control module USB interface 20 is connected to the sensor data of the monorail crane electronic control system and supplies power.

[0066] The brake block monitoring node includes a brake sensor FPC board, a brake information processing module, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a brake information processing module housing;

[0067] The brake sensor FPC board is connected to the brake information processing module, the brake information processing module is connected to the communication control module, and the communication control module is powered by a universal power supply module. The brake information processing module is installed in the brake information processing module housing, the communication control module is installed in the universal node housing, and the universal power supply module is installed in the universal power supply housing. The universal node housing, the universal power supply housing and the brake information processing module housing are adsorbed on the monorail crane body.

[0068] In one example, a monorail drawbar block and the track are in planar contact friction braking, as shown in Figure 4. As shown in Figure 5, the brake block monitoring node 7 includes a brake sensor FPC board 31, a brake information processing module 27, a universal communication control module 12, a universal power supply module, a universal node housing 25, a universal power supply housing 36, and a brake information processing module housing 35. The brake information processing module housing 35 is shown in Figure 6, and the universal power supply housing is shown in Figure 7. As shown in Figure 8 , a brake sensor FPC board 31 is attached to the side surface of the monorail crane brake block 26. The brake sensor FPC board 31 includes a temperature sensor 32, multiple FPC copper wire cables 33, and a brake sensor FPC connector 34. The temperature sensor 32 is mounted on the edge of the brake sensor FPC board 31, in the non-wear area of ​​the side surface edge of the brake block 27 in the horizontal direction of movement. The brake sensor FPC connector 34 is connected to the brake information processing module 27. Each copper wire 34 of the FPC cable is connected to each parallel chip resistor 29 of the brake information processing module 27. The FPC cable 34 is attached to the wear area of ​​the side surface of the brake block 27. The brake information processing module 27 includes a brake information processing FPC connector 30, a brake information processing connector 28, and multiple parallel chip resistors 29. The brake information processing connector 28 is connected to the brake monitoring interface 15 of the universal communication control module 12. The universal communication control module 12 is connected to a 7.4V lithium battery via the power interface 18. The braking information processing module 27 is installed in the braking information processing module housing 35, the universal communication control module 12 is installed in the universal node housing 25, and the universal power supply module is installed in the universal power supply housing 36. Magnets are installed at the bottom of the universal node housing 25, the universal power supply housing 36, and the braking information processing module housing 35. The universal node housing 25 and the braking information processing module housing 35 are adsorbed on the monorail crane braking device 6 through magnets.

[0069] Furthermore, the spacing between the copper wires is determined according to the required braking monitoring accuracy, the number of copper wires is determined by the thickness of the wear area of ​​the brake block, and the inner circle of the brake sensor FPC board fits the outer edge of the friction end face of the brake block; the temperature sensor is installed in the non-wear area of ​​the brake block on the brake sensor FPC board, in a horizontal position in the forward direction of the brake block side surface, to monitor the maximum temperature of the brake block side surface.

[0070] Furthermore, the braking information processing module includes a voltage-dividing chip resistor and multiple parallel chip resistors. Each parallel chip resistor is connected to a circuit of copper wire wiring to form multiple parallel loops. The general communication control module collects the total voltage and temperature sensor data of the parallel resistor circuit and uploads it. The data display processing equipment determines the amount of wear based on the collected voltage value.

[0071] The tie rod stress monitoring node includes a stress information processing module, a full-bridge strain gauge, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a stress information processing module housing;

[0072] The full-bridge strain gauge is connected to the stress information processing module, the stress information processing module is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the full-bridge strain gauge is pasted on the horizontal direction of the outer end surface of the monorail crane pull rod earring, the stress information processing module is installed in the stress information processing module shell, the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell. The universal node shell, the universal power supply shell and the stress information processing module shell are adsorbed on the monorail crane body.

[0073] In one example, as shown in Figure 9, the tie rod stress monitoring node 5 includes a stress information processing module 40, a full-bridge strain gauge 37, a universal communication control module 12, a universal power supply module, a universal node housing 25, a universal power supply housing 36, and a stress information processing module housing 45. The stress information processing module housing is shown in Figure 10. The stress information processing module 40 includes a stress information processing connector 41, a full-bridge strain gauge connector 43, a voltage amplification module 44, and a low-pass filter module 42. The full-bridge strain gauge 37 is affixed horizontally to the outer end of the monorail tie rod ring 39 and connected to the full-bridge strain gauge connector 43 of the stress information processing module 40. The stress information processing connector 41 is connected to the stress monitoring interface 16 of the universal communication control module 12. The universal communication control module 12 is connected to the universal power module's 7.4V lithium battery via the power supply interface 18. The universal communication control module 12 is installed in the universal node shell 25, the universal power supply module is installed in the universal power supply shell 26, and the stress information processing module 40 is installed in the stress information processing module shell 45. Magnets are installed at the bottom of the universal node shell 25, the universal power supply shell 36 and the stress information processing module shell 45, and are adsorbed on the monorail crane locomotive rod 4 through the magnets.

[0074] Furthermore, the installation position of the full-bridge strain gauge 37 is shown in Figure 11. The full-bridge strain gauge is pasted in the horizontal direction of the outer end face of the pull rod earring. It is the maximum normal stress component of the outer end face of the pull rod earring obtained by finite element analysis. After amplification and filtering by the stress information processing module, the full-bridge strain gauge output voltage signal is between 0-3.3V, and the general communication control module collects the voltage signal and uploads it.

[0075] The carriage vibration monitoring node includes a universal communication control module, an acceleration sensor, a universal power supply module, a universal node housing and a universal power supply housing;

[0076] The acceleration sensor is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell, and the universal node shell and the universal power supply shell are adsorbed on the monorail crane body.

[0077] In one example, as shown in Figure 12, the carriage vibration monitoring node 9 includes a universal communication control module 12, an accelerometer, a universal power module, a universal node housing 25, and a universal power housing 36. The accelerometer is connected to the universal communication control module 12 via the vibration monitoring interface 22, and the universal power module's 7.4V lithium battery is connected to the universal communication control module 12 via the power interface 18. The universal communication control module 12 is installed in the universal node housing 25, and the universal power module is installed in the universal power housing 36. Magnets are installed at the bottom of the universal node housing 25 and the universal power housing 36, allowing them to be attached to the monorail locomotive carriage 8.

[0078] The routing relay node 10 includes a universal communication control module 12, a universal power module, a universal node housing 25, and a universal power housing 36. The routing relay node 10 is installed within the universal node housing 25, and the universal power module is installed within the universal power housing 36. The universal node housing 10 and the universal power housing 36 are attached to the monorail crane body via magnets. The routing relay nodes 10 are deployed at uneven spacing on the monorail crane body, each collecting and uploading data from monitoring sensor nodes.

[0079] The data display and processing equipment includes a data display and storage module and a data analysis and processing module, wherein the data display and storage module includes a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module and a display storage and data transmission module; the data analysis and processing module includes an analysis and processing data transmission module, a mathematical model data processing module and a deep learning data processing module;

[0080] The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module. The data storage module stores the received data. The data sending module issues instructions to the monitoring node through the TCP communication module. The data receiving module displays the received raw data frames. The data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the data analysis and processing module, and the display storage and data transmission module transmits data to the data analysis and processing module.

[0081] The data analysis and processing module analyzes and processes the received data, imports the mathematical model data processing module and the deep learning data processing module. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability of the monorail crane in the complex frequency domain based on the vibration signals of each carriage of the monorail crane. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the operating status of the monorail crane, including the locomotive health status, operating status and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module.

[0082] In one example, the data processing device 11 includes a host computer data display and storage module and a data analysis and processing module. The data display and storage module is developed using LabVIEW and includes a TCP communication module, a data storage module, a data transmission module, a data receiving module, a data display module, an alarm module, and a display storage and data transmission module. The data analysis and processing module is developed using Python and includes an analysis and processing data transmission module, a mathematical model data processing module, and a deep learning data processing module. The data display and storage module receives and sends data to the coordinator aggregation node through the TCP communication module. The data storage module stores the received data. The data sending module issues instructions to the monitoring node through the TCP communication module. The data receiving module displays the received original data frame. The data display module classifies and processes the received data frame, displays the actual monitoring parameters and the analysis results of the data analysis and processing module, and displays the storage data transmission module to transmit the data to the data analysis and processing module; the data analysis and processing module analyzes and processes the received data, and imports the mathematical model data processing module and the deep learning data processing module respectively. The mathematical model data processing module performs complex frequency domain calculation on the vibration signals of each carriage of the monorail crane to obtain the Sperling index of locomotive operation stability. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the status of the monorail crane, such as locomotive health status, operation status, and track status, and feeds back to the data storage module through the analysis and processing data transmission module.

[0083] The working principle of the underground monorail crane wireless sensor monitoring network is as follows:

[0084] A Zigbee network is established using the coordinator aggregation node 3, connected to the tunnel WIFI base station, and the routing relay node 10 joins the Zigbee network. The brake monitoring node 7, the pull rod stress monitoring node 5, and the car vibration monitoring node 9 connect to the nearest routing relay node 10 to join the Zigbee network. The monitoring node collects data and uploads it to the routing relay node 10. The routing relay node 10 receives the child node data and uploads it. The coordinator node 3 receives the node data and the electronic control system parameters and uploads them to the tunnel base station via WIFI. The data display and processing device 11 receives the data. The data display module distinguishes the data frames and determines the actual location of the data, displays the data in a graphical form and records it, and displays the results of the data analysis and processing module. The data analysis and processing module calculates the Sperling operation stability index based on the acceleration complex frequency domain of the monitoring data, and judges the locomotive operation status, health status, and track status according to the monitoring data and the electronic control system parameters using the neural network.

[0085] The monitoring network of the present invention is easy to install and maintain, safe, reliable, and low-cost. It does not damage the monorail crane locomotive or affect its normal operation. The nodes are powered by rechargeable, environmentally friendly, and reusable lithium batteries. It addresses vulnerabilities in existing monorail crane electronic control monitoring systems and provides supplementary monitoring for brakes, tie rods, and vibration, which are difficult to monitor with hydraulic electronic control systems. The present invention uses FPC cables to detect brake shoe wear. Compared with traditional manual shoe inspection, the present invention offers a novel, less sensitive, and more reliable detection method. The detection accuracy can be adjusted based on the spacing of the copper wires, enabling real-time monitoring of shoe thickness and temperature even while the monorail crane is in operation. The present invention monitors tie rod stress, the primary load-bearing component of each monorail crane section. It proposes monitoring the horizontal normal stress on the outer end face of the tie rod earring, a unique point in the tie rod stress distribution whose magnitude effectively reflects earring wear changes. The present invention also monitors monorail crane car vibration, a key evaluation indicator for rail transportation equipment, by addressing car monitoring vulnerabilities in three-axis vibration acceleration and three-axis roll angle. The communication control system of the present invention adopts Zigbee chip as the core processor, which can accurately realize data collection and sensor network data transmission, is easy to network, and can increase the number of monitoring nodes according to the length and structure of the monorail crane. The coordinator aggregation node of the present invention adopts WIFI module to upload data, and uploads it to the locomotive monitoring room in real time according to the wireless communication base station installed in the mine tunnel, without adding additional base station equipment. The data display storage program of the present invention receives sensor network data frames from TCP, judges the data frame category and actual node position, and the user can observe in real time. The data display is intuitive and clear, there is a threshold alarm, and historical data is retained. The present invention monitors the overall drawbar stress and car vibration of the monorail crane locomotive in real time, and can achieve real-time monitoring and alarm for major transportation accidents that may occur during operation, such as falling off the track, running away, collision, etc. The present invention adopts deep learning neural network to train the characteristic data of monorail crane braking, drawbar, car vibration, electronic control system parameters, etc., and can analyze and judge various operating states and structural problems of the monorail crane, and calculate the Sperling index of locomotive operation evaluation based on car vibration acceleration to judge its operating stability.

[0086] Example 2

[0087] The wireless sensor monitoring method for an underground monorail crane described in this embodiment is applied to the wireless sensor monitoring network for an underground monorail crane constructed in Example 1. The monitoring method specifically includes the following steps:

[0088] Step 1: Create a wireless sensor network using the coordinator sink node;

[0089] Step 2: Use the brake monitoring node to collect brake shoe wear and temperature data, use the tie rod stress monitoring node to collect the horizontal normal stress of the outer end face of the tie rod earring, and use the car vibration monitoring node to collect the three-axis vibration acceleration and three-axis roll angle of the car;

[0090] Step 3: Use the routing relay node to collect the data of nearby monitoring nodes and upload it to the routing relay node;

[0091] Step 4: Use the coordinator aggregation node to collect Zigbee data from all nodes and collect sensor data from the monorail crane electric control system through the USB interface. Upload the data to the WiFi base stations installed at intervals on the walls of the mine tunnels via WiFi. The WiFi base stations are connected to the mine Ethernet ring network.

[0092] Step 5: The data display and processing device receives the monitoring network data through the mine Ethernet ring network, including:

[0093] The data display and storage module classifies and locates the data frames collected by the node, including brake pad temperature, wear, rod stress, car vibration acceleration, roll angle, and electronic control system sensors, and displays and stores them in real time, generating alarms based on pre-set thresholds.

[0094] The mathematical model data processing module of the data analysis and processing module evaluates the locomotive's operating stability based on the Sperling index in the complex frequency domain of vibration acceleration and roll angle. The deep learning data processing module of the data analysis and processing module determines the locomotive's operating status and extracts features based on the temperature and wear of each brake block, the stress data of each tie rod, the triaxial acceleration and triaxial roll angle data of each carriage, and the sensor data of the locomotive's electronic control system, corresponding to the monorail crane's operating status.

[0095] The deep learning data processing module analyzes the structural abnormalities of the monorail crane track based on stress and vibration data, and makes track status judgments and early warnings for track misalignment. At the same time, based on the monitoring network data and the sensor data parameters of the monorail crane's electronic control system, it extracts features of common operating faults of the monorail crane, and judges and issues early warnings on the health status of the monorail crane based on the monitoring parameters.

[0096] As shown in Figure 16, the implementation process of the underground monorail crane wireless sensor monitoring method is as follows:

[0097] (1) The monorail crane coordinator aggregation node 3 is installed in the monorail crane cab 2 to create a wireless sensor network. The Zigbee communication collects the data of each node and the parameters of the locomotive electronic control system and uploads them to the roadway WIFI base station through serial communication via the WIFI module. The WIFI base station is connected to the mine roadway Ethernet ring network and finally uploaded to the data display and processing equipment 11 located in the locomotive monitoring and dispatching room through TCP communication. The monorail crane brake monitoring node 7, the tie rod stress monitoring node 5, and the car vibration monitoring node 9 are correspondingly installed on all the brake devices 6, tie rods 4, and cars 8 of the monorail crane in a linear deployment state. The monorail crane routing relay nodes 10 are installed on the monorail crane body in an uneven deployment. The routing relay nodes 10 close to the coordinator aggregation node 3 have a short distance, while the routing relay nodes 10 far away from the coordinator aggregation node 3 have a long distance.

[0098] (2) The braking motion of the brake block 26 on the monorail track 1 is subjected to a dynamic thermo-rigid coupling finite element analysis. The results are shown in FIG13 , which shows that the temperature distribution pattern of the friction end surface between the brake block 27 and the track 1 is that the temperature at the center of the brake block is the highest, followed by the horizontal direction of the brake block, and the temperature of the end surface of the brake block 27 in the direction perpendicular to the running direction of the brake block 27 is the lowest. In order to measure the highest temperature of the end surface of the brake block 27 as much as possible, the temperature sensor 32 of the brake sensor FPC board 31 is installed on the side surface of the brake block 27 in the horizontal direction of the brake block 27. The temperature sensor 32 communicates with the general communication control module 12 through a single bus. By performing transient structural wear finite element analysis on the braking movement of the brake block 26 on the monorail hanging track 1, the results are shown in Figure 14. The wear on the friction end face of the brake block 27 and the track 1 is greater in the forward direction. In order to measure the maximum wear of the end face of the brake block 27, the inner circle of the wear monitoring FPC board 32 is designed with parallel and evenly distributed FPC copper wire cables 33. When the end face of the brake block 27 is worn, the innermost wire of the FPC copper wire cable 33 is worn and disconnected, and the parallel chip resistor 29 circuit of the corresponding braking information processing module 27 is disconnected. The parallel resistor 30 circuit disconnects a parallel circuit, and the total voltage of all parallel resistors 30 collected by the general communication control module 12 changes. The collected voltage value and temperature pass through the routing relay node 10 via Zigbee communication. Finally, the data display processing device 11 compares the obtained voltage value with the corresponding wear amount to obtain the wear amount of the brake block 27 in real time.

[0099] (3) Through the finite element analysis of the static structure of the monorail suspension rod 38, the rod 38 is subjected to tension at both ends. As shown in Figure 15, the maximum equivalent stress is located at the rod earring 39. The normal stress in the horizontal direction of the equivalent stress on the outer end face of the rod earring 39 is the main component. When the rod earring 39 and the rod are connected at the fish mouth, the normal stress on the outer end face of the rod earring 39 will also change significantly. The normal stress in the horizontal direction of the outer end face of the rod earring 39 is measured by the full-bridge strain gauge 37. After passing through the stress information processing module 40, the voltage amplification module 44 and the low-pass filter module 42, the general communication control module 12 finally collects the analog value of its voltage. The data display processing device 11 can observe the stress changes of the rod 38 in real time and issue timely warnings.

[0100] (4) The monorail crane car vibration monitoring node 9 collects the three-axis acceleration and three-axis roll angle of the monorail crane car body in real time through the six-axis motion processing sensor via IIC communication, and converges them to the coordinator aggregation node 3 through the routing relay node 10.

[0101] (5) The data display and processing device 11 includes a data display storage module and a data analysis and processing module. The data display storage module receives data and sends data to the coordinator aggregation node 3 through the TCP communication module. The data storage module stores the received data. The data sending module issues instructions to the monitoring node through the TCP communication module. The data receiving module displays the received raw data frames. The data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits the data to the data analysis and processing module. The data analysis and processing module analyzes and processes the received data and imports the mathematical model data processing module and the deep learning data processing module respectively. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability of each car vibration signal of the monorail crane in the complex frequency domain. The deep learning data processing module uses the locomotive braking, pull rod stress, car vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to extract features of various states of the monorail crane, such as locomotive health state, operation state, and track state. Through the locomotive electronic control parameters such as engine speed, oil temperature and oil pressure, hydraulic system hydraulic pressure and other parameters, and the parameters collected by the sensor monitoring nodes, characteristic information is extracted to issue early warnings for common health problems of the monorail crane, such as engine status and leakage. The operating status of the monorail crane, such as braking in flat and inclined lanes, uphill and downhill, acceleration and deceleration, and driving on curves, is monitored through the three-axis acceleration and tie rod stress parameters. The running track status, such as anchor rod descent and track error, is analyzed through vibration signals. The data is analyzed and processed by the data transmission module and fed back to the data display and storage module.

Claims

1. An underground monorail crane wireless sensor monitoring network, characterized in that: It includes a coordinator aggregation node, a data display and processing device, and multiple brake block monitoring nodes, a tie rod stress monitoring node, a carriage vibration monitoring node, and a routing relay node; The brake block monitoring node, the rod stress monitoring node, and the carriage vibration monitoring node are respectively connected to the routing relay node through the universal communication control module, the routing relay node is connected to the coordinator aggregation node through the universal communication control module, and the coordinator aggregation node is connected to the data display and processing device through the universal communication control module; The brake block monitoring nodes are distributed and installed on the monorail crane braking device to collect the wear and temperature data of the brake block; The tie rod stress monitoring node is installed on the monorail suspension tie rod to monitor the tie rod stress condition in real time; The carriage vibration monitoring node is installed on the monorail crane carriage to monitor the three-axis vibration acceleration and three-axis roll angle of the carriage in real time; The routing relay node is installed on the body of the monorail crane locomotive to collect and forward the data of the nodes in the cluster; The coordinator aggregation node is installed in the monorail crane cab and is used to collect all node data and locomotive electronic control parameters in the monitoring network; The data display and processing equipment is set up in the mine tunnel locomotive dispatching room, and receives all node data and locomotive electronic control parameters through the mine Ethernet ring network.

2. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The brake block monitoring node includes a brake sensor FPC board, a brake information processing module, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a brake information processing module housing; The brake sensor FPC board is connected to the brake information processing module, the brake information processing module is connected to the communication control module, the communication control module is powered by the universal power supply module, the brake information processing module is installed in the brake information processing module housing, the communication control module is installed in the universal node housing, the universal power supply module is installed in the universal power supply housing, and the universal node housing, the universal power supply housing and the brake information processing module housing are adsorbed on the monorail crane body.

3. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The tie rod stress monitoring node includes a stress information processing module, a full-bridge strain gauge, a universal communication control module, a universal power supply module, a universal node housing, a universal power supply housing and a stress information processing module housing; The full-bridge strain gauge is connected to the stress information processing module, the stress information processing module is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the full-bridge strain gauge is pasted on the horizontal direction of the outer end surface of the monorail crane pull rod earring, the stress information processing module is installed in the stress information processing module shell, the universal communication control module is installed in the universal node shell, the universal power supply module is installed in the universal power supply shell, and the universal node shell, the universal power supply shell and the stress information processing module shell are adsorbed on the monorail crane body.

4. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The carriage vibration monitoring node includes a universal communication control module, an acceleration sensor, a universal power supply module, a universal node housing and a universal power supply housing; The acceleration sensor is connected to the universal communication control module, and the universal communication control module is powered by the universal power supply module; the universal communication control module is installed in the universal node shell, and the universal power supply module is installed in the universal power supply shell, and the universal node shell and the universal power supply shell are adsorbed on the monorail crane.

5. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The data display and processing device includes a data display storage module and a data analysis and processing module, wherein the data display storage module includes a TCP communication module, a data storage module, a data sending module, a data receiving module, a data display module, an alarm module and a display storage data transmission module; the data analysis and processing module includes an analysis and processing data transmission module, a mathematical model data processing module and a deep learning data processing module; The data display and storage module receives data and sends data to the coordinator aggregation node through the TCP communication module, the data storage module stores the received data, the data sending module issues instructions to the monitoring node through the TCP communication module, the data receiving module displays the received raw data frames, the data display module classifies and processes the received data frames, displays the actual monitoring parameters and the analysis results of the display data analysis and processing module, and the display storage data transmission module transmits data to the data analysis and processing module; The data analysis and processing module analyzes and processes the received data, imports the mathematical model data processing module and the deep learning data processing module. The mathematical model data processing module calculates the Sperling index of the locomotive operation stability based on the vibration signals of each carriage of the monorail crane in the complex frequency domain. The deep learning data processing module uses the locomotive braking, pull rod stress, carriage vibration and locomotive electronic control system sensor data collected by the monitoring node as network input to judge the operating status of the monorail crane, including the locomotive health status, operating status and track status, and feeds back to the data display and storage module through the analysis and processing data transmission module.

6. The underground monorail crane wireless sensor monitoring network according to claim 2 is characterized in that: The brake sensor FPC board includes copper wire cables, temperature sensors and FPC connectors. The spacing between the copper wire cables is determined according to the required brake monitoring accuracy, and the number of copper wire cables is determined by the thickness of the wear area of ​​the brake block. The inner circle of the brake sensor FPC board fits the outer edge of the friction end face of the brake block; the temperature sensor is installed in the non-wear area of ​​the brake block on the brake sensor FPC board, in a horizontal position on the forward direction of the brake block side surface, to monitor the maximum temperature of the brake block side surface.

7. The underground monorail crane wireless sensor monitoring network according to claim 6 is characterized in that: The brake information processing module includes a voltage-dividing chip resistor and multiple parallel chip resistors. Each parallel chip resistor is connected to a circuit of copper wire wiring to form multiple parallel loops. The general communication control module collects the total voltage and temperature sensor data of the parallel resistor circuit and uploads it. The data display processing equipment determines the amount of wear based on the collected voltage value.

8. The underground monorail crane wireless sensor monitoring network according to claim 3 is characterized in that: The full-bridge strain gauge is pasted on the outer end face of the tie rod earring in the horizontal direction. It is the maximum normal stress component of the outer end face of the tie rod earring obtained by finite element analysis. After amplification and filtering by the stress information processing module, the full-bridge strain gauge outputs a voltage signal between 0-3.3V. The general communication control module collects the voltage signal and uploads it.

9. The underground monorail crane wireless sensor monitoring network according to claim 1 is characterized in that: The routing relay nodes are deployed on the monorail crane in a non-uniform spacing manner. Each routing relay node collects and uploads the data of the monitoring sensor nodes.

10. A method for monitoring a wireless sensor for an underground monorail crane, applied to the underground monorail crane wireless sensor monitoring network as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: Step 1, using the coordinator aggregation node to create a wireless sensor network; Step 2: Use the brake monitoring node to collect brake block wear and temperature data, use the tie rod stress monitoring node to collect the horizontal normal stress of the outer end surface of the tie rod earring, and use the car vibration monitoring node to collect the three-axis vibration acceleration and three-axis roll angle of the car; Step 3: Use the routing relay node to collect nearby monitoring node data and upload it to the routing relay node; Step 4: Use the coordinator to gather the Zigbee data of all nodes and collect the sensor data of the monorail crane electric control system through the USB interface, and upload it to the WIFI base station installed at intervals on the wall of the mine tunnel through WIFI. The WIFI base station connects to the mine. Well Ethernet ring network; Step 5: The data display processing device receives the monitoring network data through the mine Ethernet ring network, including: The data display and storage module classifies and locates the data frames of multiple brake block temperatures, wear, rod stress, car vibration acceleration, roll angle, and electronic control system sensors collected by the node, displays and stores them in real time, and issues alarms based on pre-set thresholds; The mathematical model data processing module of the data analysis and processing module evaluates the locomotive running stability according to the Sperling index in the complex frequency domain of vibration acceleration and the roll angle; the deep learning data processing module of the data analysis and processing module judges the running status of the locomotive, extracts features according to the temperature and wear of each brake block, the stress data of each tie rod, the three-axis acceleration of each car vibration, the three-axis roll angle data and the sensor data of the locomotive electronic control system, and corresponds to the running status of the monorail crane; The deep learning data processing module analyzes the structural abnormalities of the monorail crane track based on stress and vibration data, and makes track status judgments and early warnings for track misalignment. At the same time, based on the monitoring network data and the sensor data parameters of the monorail crane's electronic control system, it extracts features of common operating faults of the monorail crane, and judges and issues early warnings on the health status of the monorail crane based on the monitoring parameters.

Images