阅读说明：本技术 一种应用于起重机械领域的智能滑轮组 (Be applied to intelligent assembly pulley in hoisting machinery field ) 是由 焦倩倩 秦义校 张灏 谷金朋 于 2020-06-04 设计创作，主要内容包括：本发明涉及一种应用于起重机械领域的智能滑轮组,属于智能化重型装备领域。该装置在滑轮轴应力最大处粘贴应变片,将数据传到数据处理中心,并实时监测滑轮轴的变形情况；在滑轮轴支撑板或挂板之间安装轴压式传感器,以便测量和限制起重量；在滑轮组的每个滑轮上方都安装一个滑轮转数计数传感器,其引线均通过空心杆与接线盒连接,接线盒内设置数据远程发射器；嵌入在轴承的静止套圈上的无线测温系统将温度信号无线传输到地面数据处理中心；在衬套下方安装的噪音探测头的引线通过滑轮轴上的钻孔引至轴端,进行噪音数据无线传输。与传统滑轮组相比,本发明智能滑轮组具备感知和物联网远程监控功能,有较高的可靠性和灵敏度。(The invention relates to an intelligent pulley block applied to the field of hoisting machinery, and belongs to the field of intelligent heavy equipment. The device is characterized in that a strain gauge is adhered to the position with the maximum stress of a pulley shaft, data are transmitted to a data processing center, and the deformation condition of the pulley shaft is monitored in real time; installing a pressure sensor between the pulley shaft supporting plates or the hanging plates so as to measure and limit the hoisting capacity; a pulley revolution counting sensor is arranged above each pulley of the pulley block, lead wires of the pulley revolution counting sensor are connected with a junction box through hollow rods, and a data remote transmitter is arranged in the junction box; the wireless temperature measuring system embedded in the static ferrule of the bearing wirelessly transmits the temperature signal to a ground data processing center; and a lead wire of a noise detecting head arranged below the bushing is led to the shaft end through a drill hole in the pulley shaft to carry out wireless transmission of noise data. Compared with the traditional pulley block, the intelligent pulley block has sensing and Internet of things remote monitoring functions and has higher reliability and sensitivity.)

1. The utility model provides an intelligent assembly pulley for hoisting machinery field, includes axle deformation real-time supervision device, plays and overload limiting device, pulley jamming monitoring devices, bearing temperature monitoring devices and bearing noise monitoring devices, its characterized in that, the assembly pulley adopts multiple intelligent monitoring devices, has perception and thing networking remote monitoring function.

2. The device for real-time monitoring of shaft deformation according to claim 1, wherein a strain gauge is attached to the pulley shaft where the stress is maximum.

3. The crane overload limiting apparatus of claim 1, wherein a compression sensor is mounted between the pulley axle support plates or the clevis.

4. The sheave seizure monitoring device of claim 1 wherein a sheave revolution counter sensor is mounted above each sheave of the set of sheaves and a sensor strip is mounted in each sheave groove, the counter counting each revolution of the sheave, and the lead is mounted in the hollow bar.

5. The bearing temperature and noise monitoring device of claim 1, wherein the wireless temperature monitoring system is embedded in a stationary ring of the bearing and the noise probe is mounted below the bushing.

Technical Field

The invention belongs to the field of crane safety application, and particularly relates to an intelligent pulley block applied to the field of hoisting machinery.

Background

The pulley block is widely applied to a pulley device and a lifting appliance of a lifting mechanism of a crane, is an important part related to safety in the crane, and is a key for realizing a lifting function of the crane. The pulley replacement cycle on heavy machinery is short, has increased the cost of enterprise. When the crane lifts goods, a certain lifting limit is provided, in the normal lifting process, the bearing value of the pulley design is exceeded, the conventional lifting equipment has no lifting overload limit, the lifting equipment is lost when the bearing value exceeds the lifting maximum limit, and the work cannot be normally carried out. The heavy objects can be smashed and fall in serious accidents, so that the safety of workers is endangered, and huge economic loss is caused to enterprises. The real-time monitoring of the stress deformation of the pulley is very important.

The pulley block is sleeved on the pulley shaft, and for a large-tonnage crane, the multiplying power of the pulley block is high, and with the increase of the tonnage, a larger multiplying power is possibly needed, and more pulleys on the pulley shaft are also needed. The pulley shaft is also an important part in the crane, and the real-time monitoring of the stress deformation of the pulley shaft is necessary.

The steel wire rope is wound on the pulley, the movement of the steel wire rope can drive the pulley to move, once the pulley is blocked, the steel wire rope and the pulley can move relatively, the steel wire rope is seriously abraded, and the pulley blocking condition is monitored in real time.

The bearing is an important rotating part, the damage of the bearing is avoided, the state monitoring is an important link in the preventive maintenance, advanced monitoring instruments are not arranged in all hoisting equipment, and the temperature and the noise of the bearing must be kept highly alert.

In conclusion, the intelligent pulley block has a certain engineering value and has a wide application prospect in the field of hoisting machinery.

Disclosure of Invention

The invention aims to provide an intelligent pulley block applied to the field of hoisting machinery, which comprises a shaft deformation real-time monitoring device, a hoisting overload limiting device, a pulley clamping stagnation monitoring device, a bearing temperature monitoring device and a bearing noise monitoring device.

In order to achieve the purpose, the invention discloses an intelligent pulley block scheme applied to the field of hoisting machinery, which comprises the following steps: a shaft pressure type sensor (14) is arranged between the pulley shaft supporting plates or the hanging plates, and a lead (4) of the shaft pressure type sensor (14) can be connected into the hollow rod (2); the hollow rod (2) is fixed on a pulley shaft, a pulley revolution counting sensor (3) is arranged above each pulley (1) of the pulley block through the hollow rod (2), a lead (4) is arranged in the hollow rod (2), the connected pulley revolution counting sensors (3) are connected with a junction box through the lead (4), and a data remote transmitter is arranged in the junction box; strain gauges (13) are adhered to the positions right below the pulleys at the middle and two ends of the pulley shaft (5), and are distributed as shown in the figure; a signal processor (20) is arranged at two ends of the pulley shaft (5), a lead (4) of a strain gauge (13) adhered on the pulley shaft (5) is led to a lubricating oil channel (19) through a lubricating oil hole (18), or a hole (21) is drilled on the pulley shaft (5) to be led to the lubricating oil channel (19) and finally led to the shaft end; the transmitting coil (8) and the receiving coil (9) are sleeved on the bearing boss, two bearings (6) are sleeved under one pulley, a piston ring (7) is arranged between the bearings (6) and the bearings, and a bearing temperature detection system (11) is arranged below the piston ring (7) and mainly comprises a temperature acquisition system (temperature detector) (12) and a wireless data transmission and wireless energy supply (wireless power supply stage) (10); a noise detecting head (15) is arranged below a bush between the bearing (6) and the bearing (6), and a lead wire (4) of the noise detecting head (15) is led to a lubricating oil channel (19) or a lubricating oil hole (18) through a drill hole (21) on a pulley shaft and finally led to the shaft end.

For the crane with smaller tonnage, only a single lubricating hole is needed. For large-tonnage cranes, a plurality of lubrication holes are formed on the pulley shaft, and generally, two lubrication holes, three lubrication holes and four lubrication holes are provided, preferably four lubrication holes are provided. Wherein the main oil gallery is in a half-through state, the diameter is 18mm, the diameter of the oil through hole is 6mm, and the arrangement is optimally arranged. For a large-tonnage lifting appliance pulley shaft, the ratio of the shaft diameter to the diameter of the lubricating hole is large, and the lubricating hole has little influence on the mechanical property of the shaft.

The pulley shaft is provided with a slot at the position where the strain gauge needs to be adhered, the strain gauge and a lead wire of the noise detection head are led to an oil duct or an oil hole through drilling on the pulley shaft and finally led to the shaft end, and the change of the pulley shaft does not affect the service life and the fatigue strength.

At present, the numerical control lathe is basically popularized, the change of the pulley shaft can be added into a processing code and a program, and a numerical control machine operating system can meet the processing requirement of a complex pulley shaft.

In order to adapt to the change of the pulley shaft, the bearing is also reselected as a reinforced bearing, and meanwhile, the pulley is also modified: the thickness of the pulley needs to be increased.

The general principle of strain gauge measuring point arrangement is that under the known stress condition, the position and the direction of sticking the strain gauge are arranged according to the structural shape characteristics of the deformation body.

The strain gauge collects the stress of the pulley shaft, the fixed pulley shaft is processed into a simply supported beam with a hollow circular ring section, and details such as oil through holes are not considered. The load of the fixed pulley block is processed into uniformly distributed load. When the beam is bent, the maximum positive stress occurs at the point farthest from the neutral axis, at the cross-section where the bending moment is the largest. For a simply supported beam bearing uniformly distributed load, the bending moment value at the midspan position is the largest, the shearing force is zero, and the simply supported beam is bent.

Calculation formula of pure bending normal stress: sigma_max=M_max/W_Z， M_max=0.125ql²，W_Z=πD³(1-α⁴)/32，α=d/D。

In the formula: sigma_maxAt maximum positive stress, M_maxMaximum bending moment, W_ZIn order to obtain a bending-resistant section coefficient,for load, l is the axial length and D is the cross-sectional diameter.

Taking a 180t lifting hook pulley shaft as an example, Ra = Rb =900000(N), and the pulley shaft is quenched and tempered by CrMo steel, [ sigma ]]=σ_S/2.5=200(N/mm²)。

If the original pulley shaft size is adopted to arrange intelligent equipment, D =300mm,

W=πD³/32=3.14×300³/32=2649375(mm³)，

σ=M/W=2404800000/2649375=907(N/mm²)，

it is found that σ > [ σ ], therefore, the strength of the pulley shaft does not satisfy the requirement.

If the intelligent equipment is arranged by adopting the improved pulley shaft size, D =500mm,

W=πD³/32=3.14×500³/32=56106599(mm³)，

σ=M/W=2404800000/56106599=196(N/mm²)，

it is found that σ < [ σ ], so the strength of the pulley shaft satisfies the requirement. The maximum value of the sling weight should be limited within this range.

The pulley shaft has a very simple structure and a circular cross section. By establishing a finite element model and analyzing the displacement and stress distribution of the pulley shaft, it is found that the maximum displacement occurs at the center of the shaft, and therefore, the strain gauge is adhered at the center of the shaft.

A common steel wire rope penetrating and winding method for a hoisting pulley block is a two-line single pulley block penetrating method, and when the hoisting pulley block based on the method is used for hoisting, the stress on two sides of a free end is relatively large. Therefore, the strain gauges are adhered to two sides of the shaft and right below the pulleys.

The influence of the temperature of the use environment on the strain gauge is great, the strain gauge made of different materials is selected according to the use temperature, and the use temperature of the high-temperature strain gauge is indicated when ordering if needed.

In the assembly pulley, the jamming phenomenon can appear in every pulley, so all install pulley revolution count sensor above every pulley, every pulley race installation response piece, every round of pulley, pulley revolution count sensor count once. The pulley revolution counting sensor is cleared before counting, the numerical value of the pulley revolution counting sensor is compared after each lifting working cycle is carried out, if the numerical value difference of each pulley revolution counting sensor is not large, the condition that a steel wire rope slips is indicated, and the phenomenon belongs to a normal phenomenon. If the difference between the number of revolution counting sensor of the individual pulley and the number of revolution counting sensors of other pulleys is large, the pulley is stuck, the pulley corresponding to the number of revolution counting sensor of the pulley is checked, and if no problem exists, the condition of the bearing is further checked.

The lead wire of the pulley revolution counting sensor is led into the shaft hole through the hollow rod to be connected with the junction box, and a data remote transmitter is arranged in the junction box.

The axial pressure type sensor is arranged between the pulley shaft supporting plates or the hanging plates and is very sensitive to overload of the crane, and when a lifted heavy object exceeds a limit value of the axial pressure type sensor, the transmission of the pulley block is limited.

The temperature is an important index for measuring the service performance of the bearing, and the local instantaneous temperature rise and thermal failure are main failure causes of the bearing. The temperature of the inner ring is far higher than that of the outer ring at high speed, and the research on the temperature monitoring technology of the inner ring of the bearing at high speed is very important.

The service space of the bearing is very narrow, and the distribution space of the sensor is very limited. The circuit design is simplified as much as possible, and the size of the bearing is properly increased.

Real-time transmission of data is particularly important during the testing process. The bearing inner ring rotates at a high speed, and the traditional data transmission mode by using a wire is difficult to realize, so that the system adopts a wireless data transmission mode. Due to factors such as long-time monitoring requirements and space limitations, a wireless electromagnetic power supply mode is selected for power supply.

The bearing inner ring temperature testing system mainly comprises a temperature acquisition system, data wireless transmission and wireless energy supply. And a wireless temperature measuring system is embedded in a static ring of the bearing, and the temperature signal is transmitted to a data processing center through wireless transmission.

If the bearing is in good running condition, it will send out regular whining sound. Different noise reflects different conditions of the bearing: inadequate lubrication can result in a sharp, irregular squeak; improper bearing clearance can cause metal noise; damage to the rolling elements can cause intermittent noise; serious bearing damage can cause irregular and loud noises. And a piezoelectric acceleration sensor is arranged at the bearing to monitor different running conditions of the bearing and correspondingly process different alarm conditions.

If the sound pressure level of the measured noise of the measured bearing is more than 10dB greater than that of the background noise, the background noise can be ignored. If the actually measured noise sound pressure level of the measured bearing is less than 10dB of the background noise sound pressure level, the noise probe needs to amplify and collect signals.

Drawings

Fig. 1 is an overall view of an intelligent pulley block, in which (1) is a pulley, (2) is a hollow rod, (3) is a pulley revolution counting sensor, (4) is a lead wire, (5) is a pulley shaft, (6) is a bearing to be tested, (13) is a strain gauge, (15) is a noise probe, (16) is a pulley shaft axis, (18) is a lubricating oil hole, (19) is a lubricating oil passage, and (20) is a signal processor.

Fig. 2 is a left view of the intelligent pulley block, wherein (1) is a pulley, (2) is a hollow rod, (3) is a pulley revolution counting sensor, (4) is a lead wire, (14) is a shaft pressing type sensor, and (17) is a pulley shaft supporting plate or a hanging plate.

Fig. 3 is a front view of distribution of oil passages of the oil hole of the pulley shaft, wherein (4) is a lead wire, (13) is a strain gauge, (15) is a noise probe, (16) is the axis of the pulley shaft, (18) is a lubricating oil hole, (19) is a lubricating oil passage, and (20) is a signal processor.

Fig. 4 is a cross-sectional view of the distribution position of the strain gauge of the pulley shaft, wherein (13) is the strain gauge, and (16) is the axis of the pulley shaft.

Fig. 5 is a cross-sectional view showing distribution of oil passages of the oil holes of the pulley shaft, wherein (5) is the pulley shaft, (16) is the axis of the pulley shaft, (18) is a lubricating oil hole, and (19) is a lubricating oil passage.

Fig. 6 is a partial enlarged view of the bearing temperature detection system, in which (6) is the bearing to be detected, (7) is the piston ring, (8) is the transmitting coil, (9) is the receiving coil, (10) is the wireless power supply stage, (11) is the test system, and (12) is the temperature detector.

Fig. 7 is an enlarged view of the arrangement of the pulley shaft strain gauge and the noise detector, wherein (1) is a pulley, (4) is a lead wire, (6) is a bearing to be detected, (13) is a strain gauge, (15) is a noise detector, and (21) is a borehole.

Detailed Description

In order to more clearly understand the technical content of the present invention, the technical solution of the present invention is further described with reference to the accompanying drawings.

As shown in fig. 1-7, an intelligent pulley block applied to the field of hoisting machinery: a shaft pressure type sensor (14) is arranged between the pulley shaft supporting plates or the hanging plates, a lead (4) of the shaft pressure type sensor (14) can be connected into the hollow rod (2), the sensor (14) is sensitive to overload of the hoisting, and when the hoisting weight exceeds the limit value of the shaft pressure type sensor (14), the transmission of the pulley block is limited.

Hollow rod (2) are fixed on the pulley shaft, pulley revolution count sensor (3) are installed above each pulley (1) of the pulley block through hollow rod (2), and lead wire (4) are hidden in hollow rod (2) and are connected with the junction box, and a data remote transmitter is arranged in the junction box. An induction sheet is arranged in a wheel groove of each pulley (1), and the pulley revolution counting sensor (3) counts once when each pulley (1) rotates for one circle. The pulley revolution counting sensor (3) needs to be cleared before counting, the numerical value of the pulley revolution counting sensor (3) is compared after each lifting working cycle is carried out, if the numerical value difference of each pulley revolution counting sensor (3) is not large, the situation that the steel wire rope slips is shown, and the phenomenon belongs to a normal phenomenon. If the difference between the numerical value of the individual pulley revolution counting sensor (3) and the numerical value of the other pulley revolution counting sensors (3) is large, the clamping of the pulley is shown, the pulley (1) corresponding to the pulley revolution counting sensor (3) is checked, and if no problem exists, the condition of the bearing (6) is further checked.

The signal processors (20) are arranged at two ends of the pulley shaft (5), and a lead (4) of a strain gauge (13) adhered to the pulley shaft (5) is led to a lubricating oil channel (19) through a lubricating oil hole (18), or a drill hole (21) on the pulley shaft (5) is led to the lubricating oil channel (19). The strain gauge (13) collects stress data of the pulley shaft (5), and converts signals into electric signals for analysis and measurement.

Transmitting coil (8) and receiving coil (9) cover on the bearing boss, there are two bearings (6) a pulley lower cover, there is piston ring (7) between bearing (6) and bearing, bearing temperature detection system (11) are equipped with to piston ring (7) below, the temperature signal who gathers temperature detector (12) converts digital signal into, transmit to ground data processing center through wireless data transmission mode, adopt wireless power supply level (10) power supply, and then realize bearing (6) high-speed in the operation monitoring to the inner circle temperature.

A noise probe (15) is mounted below the bush, and a lead wire (4) of the noise probe (15) is led to a lubricating oil channel (19) or a lubricating oil hole (18) through a drill hole (21) in the pulley shaft. The noise signal is collected by a noise probe (15) and is sent out when the bearing (6) operates, and monitoring is carried out.

The protective scope of the present invention is not limited to the above-described embodiments, and it is apparent that various modifications and variations can be made to the present invention by those skilled in the art without departing from the scope and spirit of the present invention. It is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.