Fault double-layer redundancy monitoring method, early warning method and system

文档序号：1883546 发布日期：2021-11-26 浏览：20次中文

阅读说明：本技术 故障双层冗余监测方法、预警方法及系统 (Fault double-layer redundancy monitoring method, early warning method and system ) 是由刘宏亮付玲尹莉刘延斌张玉柱肖春良于 2021-07-26 设计创作，主要内容包括：本发明提供一种故障双层冗余监测方法、预警方法及系统,属于工程机械控制技术领域。所述方法包括：基于起重设备上按作业参数对应分组的传感器组,获得各个作业参数的传感器数据；在第一层监测中,基于所述传感器数据中相关的实际检测值是否满足配置的换算关系,确定所述起重设备是否处于第一故障工况,其中,所述换算关系包括与所述相关的实际检测值对应的作业参数之间的几何换算关系；在第二层监测中,基于所述传感器数据中与力矩对应的实际检测值是否满足与相应力矩的作业参数之间的力矩平衡关系,确定所述起重设备是否处于第二故障工况,其中,所述起重设备未处于所述第一故障工况。本发明可用于设备故障监测。(The invention provides a fault double-layer redundancy monitoring method, a fault double-layer redundancy early warning method and a fault double-layer redundancy early warning system, and belongs to the technical field of engineering machinery control. The method comprises the following steps: based on the sensor groups correspondingly grouped according to the operation parameters on the hoisting equipment, obtaining sensor data of each operation parameter; in the first-layer monitoring, whether the hoisting equipment is in a first fault working condition is determined based on whether related actual detection values in the sensor data meet a configured conversion relation, wherein the conversion relation comprises a geometric conversion relation between operation parameters corresponding to the related actual detection values; and in the second-layer monitoring, determining whether the hoisting equipment is in a second fault working condition or not based on whether an actual detection value corresponding to the moment in the sensor data meets a moment balance relation with an operation parameter of the corresponding moment, wherein the hoisting equipment is not in the first fault working condition. The invention can be used for equipment fault monitoring.)

1. A fault double-layer redundancy monitoring method is characterized by comprising the following steps:

based on the sensor groups correspondingly grouped according to the operation parameters on the hoisting equipment, obtaining sensor data of each operation parameter;

in the first-layer monitoring, whether the hoisting equipment is in a first fault working condition is determined based on whether related actual detection values in the sensor data meet a configured conversion relation, wherein the conversion relation comprises a geometric conversion relation between operation parameters corresponding to the related actual detection values;

and in the second-layer monitoring, determining whether the hoisting equipment is in a second fault working condition or not based on whether an actual detection value corresponding to the moment in the sensor data meets a moment balance relation with an operation parameter of the corresponding moment, wherein the hoisting equipment is not in the first fault working condition.

2. The method for monitoring double-layer redundancy of faults according to claim 1, wherein the hoisting device is provided with a super-lifting mechanism, and the sensor data of each operation parameter is obtained based on the sensor groups which are correspondingly grouped according to the operation parameters on the hoisting device, wherein,

the sensor groups are specifically grouped correspondingly according to the same operation key parameter,

the operation key parameters comprise any one of operation parameters related to the posture of the arm support, operation parameters related to the stroke of the counterweight and operation parameters related to the magnitude of the suspended load.

3. The method for monitoring fault double-layer redundancy according to claim 1, wherein the hoisting device is provided with a super-lifting mechanism, and the step of obtaining the sensor data of each operation parameter based on the sensor groups grouped according to the operation parameters on the hoisting device comprises the following steps:

obtaining sensor data of operational parameters related to boom attitude, wherein the sensor data comprises actual detection values in angular dependence,

the operation parameters corresponding to the actual detection values related to the angles comprise a first elevation angle of a main arm of the hoisting device, a second elevation angle of a super-lifting mast of the super-lifting mechanism and an included angle between the main arm and the super-lifting mast.

4. The method for monitoring fault dual-layer redundancy according to claim 3, wherein the lifting device further comprises a movable counterweight adjustment mechanism, and the method for obtaining sensor data of each operation parameter based on the sensor group correspondingly grouped according to the operation parameter on the lifting device further comprises:

obtaining sensor data regarding a work parameter of a counterweight stroke, wherein the sensor data includes an actual sensed value that is stroke-related,

the operation parameters corresponding to the actual detection values related to the stroke comprise a third elevation angle of a counterweight supporting arm of the movable counterweight adjusting mechanism and a counterweight real-time stroke measured aiming at the movable counterweight adjusting mechanism.

5. The fault double-layer redundancy monitoring method according to claim 4, wherein the obtaining of the sensor data of each operation parameter based on the sensor group grouped correspondingly according to the operation parameter on the hoisting equipment further comprises:

obtaining sensor data of an operational parameter related to the magnitude of the hoist load, wherein the sensor data comprises an actual detected value related to the acting force,

the operation parameters corresponding to the actual detection value related to the acting force comprise a measured pulling force at the head of the main arm, a first measured pressure at the root of the main arm and a second measured pressure at the bottom of the rear stay bar of the super-lift mast.

6. The method of claim 1, wherein determining whether the lifting device is in the first fault condition based on whether the associated actual sensed values in the sensor data satisfy the configured scaling relationships comprises:

determining a converted detection value obtained by converting the first actual detection value in the sensor data according to the configured conversion relation, and

judging whether the converted detection value is the same as a second actual detection value in the sensor data, or

Determining whether the scaled detection value falls within a specified range of values corresponding to the second actual detection value, wherein,

the conversion relation comprises a geometric conversion relation between the operation parameter corresponding to the first actual detection value and the operation parameter corresponding to the second actual detection value;

if the judged return is yes, determining that the hoisting equipment is not in a first fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the first fault working condition.

7. The method for fault dual-layer redundancy monitoring according to claim 3, wherein,

the configured conversion relation comprises that the sum of the first elevation angle, the second elevation angle and the included angle is a specified angle or belongs to a specified numerical range corresponding to the specified angle.

8. The method of claim 7, wherein determining whether the lifting device is in the first fault condition based on whether the associated actual sensed values in the sensor data satisfy the configured scaling relationships comprises:

reading actual detection values corresponding to the three in the sensor data;

and judging whether the sum of the actual detection values corresponding to the three is the specified angle or not or whether the sum belongs to the specified numerical range corresponding to the specified angle or not according to the configured conversion relation.

9. The method according to claim 8, wherein the obtaining of the specified value range comprises:

determining a sensor error amount of the arranged angle sensor;

configuring a numerical range of a first numerical value to a second numerical value to be a specified numerical range, wherein,

the first value is a difference between the specified angle and the sensor error amount,

the second value is a sum of the specified angle and the sensor error amount.

10. The method for fault dual-layer redundancy monitoring according to claim 4, wherein,

the configured conversion relation comprises that the absolute value of the difference between the converted stroke of the counterweight obtained by the third elevation angle calculation and the real-time stroke of the counterweight belongs to a specified numerical range.

11. The method of claim 10, wherein determining whether the lifting device is in the first fault condition based on whether the associated actual sensed values in the sensor data satisfy the configured scaling relationships comprises:

reading actual detection values corresponding to the third elevation angle and the real-time stroke of the counterweight in the sensor data, and determining a conversion detection value of the counterweight conversion stroke according to the actual detection value corresponding to the third elevation angle;

and judging whether the absolute value of the difference between the actual detection value corresponding to the real-time stroke of the counterweight and the converted detection value belongs to the specified numerical range or not according to the configured conversion relation.

12. The method for fault dual-layer redundancy monitoring according to claim 5, wherein,

the conversion relation of the arrangement includes that the absolute value of the difference between the first suspended load weight and the second suspended load weight is within a specified numerical range,

the first suspended load weight is obtained by converting the measured tension through a first trigonometric function relation,

and the second suspended load weight is obtained by converting the first measured pressure through a second trigonometric function relation.

13. The method of claim 12, wherein determining whether the lifting device is in the first fault condition based on whether the associated actual sensed values in the sensor data satisfy the configured scaling relationships comprises:

reading actual detection values corresponding to the measured tension and the first measured pressure in the sensor data, and respectively determining converted detection values corresponding to the first hoisting weight and the second hoisting weight;

and judging whether the absolute value of the difference between the converted detection values corresponding to the first suspended load weight and the second suspended load weight belongs to the specified numerical range or not according to the configured conversion relation.

14. The method for monitoring for failed dual-layer redundancy in accordance with claim 13, further comprising:

in the middle layer monitoring, judging whether the size grade matching relation is the matching relation corresponding to the steady state of the hoisting equipment or not, wherein,

the size grade matching relationship is a matching relationship between the size grade of a third suspended load and the size grade of the first suspended load or a matching relationship between the size grade of the third suspended load and the size grade of the second suspended load,

the magnitude grade of the third hoisting weight is obtained through the second measured pressure, and the hoisting equipment is not in the first fault working condition;

if the judged return is yes, determining that the hoisting equipment is not in a third fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the third fault working condition.

15. The method for monitoring the double-layer redundancy of the faults according to claim 5, wherein the step of determining whether the hoisting equipment is in the second fault working condition based on whether an actual detection value corresponding to the moment in the sensor data meets a moment balance relation with an operation parameter of the corresponding moment comprises the following steps:

judging whether the absolute value of the difference between the moment of the hoisting end and the moment of the counterweight end belongs to a specified numerical range corresponding to the moment balance state of the hoisting equipment or not, wherein,

the moment of the hoisting end is obtained by calculating an actual detection value related to an angle and an actual detection value related to an acting force,

the moment of the counterweight end is obtained by calculating an actual detection value related to a stroke;

if the judged return is yes, determining that the hoisting equipment is not in a second fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the second fault working condition.

16. A failure double-layer redundancy early warning method, comprising the failure double-layer redundancy monitoring method of any one of claims 1 to 15, characterized in that the failure double-layer redundancy early warning method further comprises:

determining that the hoisting equipment is in any fault working condition;

and stopping the hoisting equipment to execute hoisting operation and executing configuration early warning.

17. A failed dual-layer redundancy early warning system, comprising:

the acquisition module is used for acquiring sensor data of each operation parameter based on the sensor groups which are correspondingly grouped according to the operation parameters on the hoisting equipment;

the first-layer monitoring module is used for determining whether the hoisting equipment is in a first fault working condition or not based on whether a related actual detection value in the sensor data meets a configured conversion relation or not in first-layer monitoring, wherein the conversion relation comprises a geometric conversion relation between operation parameters corresponding to the related actual detection value;

and the second-layer monitoring module is used for determining whether the hoisting equipment is in a second fault working condition or not based on whether an actual detection value corresponding to the moment in the sensor data meets a moment balance relation with an operation parameter of the corresponding moment or not in second-layer monitoring, wherein the hoisting equipment is not in the first fault working condition.

18. The fail-safe dual-layer redundancy early warning system of claim 17, further comprising:

the early warning module is used for determining that the hoisting equipment is in any fault working condition, and

and stopping the hoisting equipment to execute hoisting operation and executing configuration early warning.

19. An electronic device, comprising:

at least one processor;

a memory coupled to the at least one processor;

wherein the memory stores instructions executable by the at least one processor, the at least one processor implementing the method of any one of claims 1 to 16 by executing the instructions stored by the memory.

20. A working machine, characterized in that the working machine is provided with an electronic device according to claim 19.

21. A computer readable storage medium storing computer instructions which, when executed on a computer, cause the computer to perform the method of any one of claims 1 to 16.

Technical Field

The invention relates to the technical field of engineering machinery control, in particular to a fault double-layer redundancy monitoring method, a fault double-layer redundancy early warning system, electronic equipment, engineering machinery and a computer readable storage medium.

Background

At present, in a hoisting process of a crawler crane and other cranes with excellent hoisting capacity, in order to improve the use efficiency of a counterweight, improve the hoisting capacity and reduce the counterweight transportation and installation cost, the conventional fixed counterweight is improved into a stroke-variable front-rear movable counterweight. Compared with a fixed counterweight, the movable counterweight can enlarge the hoisting capacity of the crane under the condition of the same counterweight size. In the hoisting operation, the movable counterweight is usually required to be suspended for use, and meanwhile, the crane control system is required to flexibly adjust the counterweight position and match to obtain a proper counterweight stroke in time or preferably in real time according to the change of the hoisting weight or moment in the hoisting process so as to keep the gravity center of the crane at the center point of the rotary support and provide a balance moment, thereby maintaining the stability of the hoisting system.

Safe, matched hoist operation and counterweight movement control is based on accurate sensor data from the crane. While the conventional safety monitoring is usually performed for a fixed counterweight, the equipment counterweight usually does not change in the hoisting operation process, the system safety margin basically does not change greatly and keeps a high level, the hoisting operation is easily limited to be performed within a safety range, but for a movable counterweight, as the hoisting operation is performed, the system adjusts the position of the counterweight according to the moment balance, the movement of the counterweight affects the system safety margin, and when a sensor fails or the sensor data is inaccurate, the counterweight moving operation performed by the system according to the sensor data of a failed element or inaccurate sensor data, such as theoretically performing counterweight push-out (or extrapolation, as compared with a rotation center) to keep balance and actually performing counterweight retraction, cannot provide a sufficient safety margin for the hoisting operation, but also aggravates the imbalance, even leading to overturning accidents. More worrisingly, before the system loses the safety margin or loses the emergency safety control capability, the sensor data which does not reach the threshold value or the fault sensor which does not alarm to reach the threshold value is difficult to be identified and found by the system, so that the basic safety guarantee of the crane of the movable counterweight is difficult to realize by using the monitoring mode of the conventional fixed counterweight.

Therefore, a multilayer monitoring scheme suitable for the movable counterweight is required to be realized for identifying whether the sensor has a fault or not or whether the sensor data has inaccuracy, so that the safety of hoisting operation is guaranteed and the occurrence of overturning accidents is avoided as much as possible.

Disclosure of Invention

The invention aims to provide a fault double-layer redundancy monitoring method, a fault double-layer redundancy early warning method and a fault double-layer redundancy early warning system, which are used for avoiding control failure of moment balance maintenance caused by the fact that a sensor or sensor data of hoisting equipment is difficult to identify and discover by a control system, and further improving the monitoring safety reliability, the control accuracy and the operation stability of the hoisting equipment.

In order to achieve the above object, an embodiment of the present invention provides a fault dual-layer redundancy monitoring method, where the fault dual-layer redundancy monitoring method includes:

based on the sensor groups correspondingly grouped according to the operation parameters on the hoisting equipment, obtaining sensor data of each operation parameter;

Specifically, the hoisting equipment is provided with a super-lifting mechanism, and the sensor data of each operation parameter is obtained based on the sensor group which is correspondingly grouped according to the operation parameter on the hoisting equipment, wherein,

the sensor groups are specifically grouped correspondingly according to the same operation key parameter,

Specifically, the obtaining of the sensor data of each operation parameter based on the sensor group correspondingly grouped according to the operation parameter on the hoisting equipment includes:

obtaining sensor data of operational parameters related to boom attitude, wherein the sensor data comprises actual detection values in angular dependence,

Specifically, the hoisting equipment further has a movable counterweight adjusting mechanism, and the sensor group correspondingly grouped according to the operation parameters on the hoisting equipment obtains the sensor data of each operation parameter, and the method further includes:

obtaining sensor data regarding a work parameter of a counterweight stroke, wherein the sensor data includes an actual sensed value that is stroke-related,

Specifically, the obtaining of the sensor data of each operation parameter based on the sensor group correspondingly grouped according to the operation parameter on the hoisting equipment further includes:

obtaining sensor data of an operational parameter related to the magnitude of the hoist load, wherein the sensor data comprises an actual detected value related to the acting force,

Specifically, the determining whether the hoisting device is in the first fault condition based on whether the actual detection value related to the sensor data satisfies the configured conversion relationship includes:

determining a converted detection value obtained by converting the first actual detection value in the sensor data according to the configured conversion relation, and

judging whether the converted detection value is the same as a second actual detection value in the sensor data, or

Determining whether the scaled detection value falls within a specified range of values corresponding to the second actual detection value, wherein,

if the judged return is yes, determining that the hoisting equipment is not in a first fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the first fault working condition.

In particular, wherein,

reading actual detection values corresponding to the three in the sensor data;

Specifically, the manner of acquiring the designated numerical range includes:

determining a sensor error amount of the arranged angle sensor;

configuring a numerical range of a first numerical value to a second numerical value to be a specified numerical range, wherein,

the first value is a difference between the specified angle and the sensor error amount,

the second value is a sum of the specified angle and the sensor error amount.

In particular, wherein,

the first suspended load weight is obtained by converting the measured tension through a first trigonometric function relation,

and the second suspended load weight is obtained by converting the first measured pressure through a second trigonometric function relation.

Specifically, the fault double-layer redundancy monitoring method further includes:

in the middle layer monitoring, judging whether the size grade matching relation is the matching relation corresponding to the steady state of the hoisting equipment or not, wherein,

the magnitude grade of the third hoisting weight is obtained through the second measured pressure, and the hoisting equipment is not in the first fault working condition;

if the judged return is yes, determining that the hoisting equipment is not in a third fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the third fault working condition.

Specifically, determining whether the hoisting equipment is in the second fault condition based on whether the actual detection value corresponding to the moment in the sensor data meets the moment balance relationship with the operation parameter of the corresponding moment includes:

the moment of the hoisting end is obtained by calculating an actual detection value related to an angle and an actual detection value related to an acting force,

the moment of the counterweight end is obtained by calculating an actual detection value related to a stroke;

if the judged return is yes, determining that the hoisting equipment is not in a second fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the second fault working condition.

The embodiment of the invention provides a fault double-layer redundancy early warning method, which comprises the fault double-layer redundancy monitoring method, and further comprises the following steps:

determining that the hoisting equipment is in any fault working condition;

and stopping the hoisting equipment to execute hoisting operation and executing configuration early warning.

The embodiment of the invention provides a fault double-layer redundancy early warning system, which comprises:

Specifically, this redundant early warning system of trouble double-deck still includes:

the early warning module is used for determining that the hoisting equipment is in any fault working condition, and

and stopping the hoisting equipment to execute hoisting operation and executing configuration early warning.

In another aspect, an embodiment of the present invention provides an electronic device, including:

at least one processor;

a memory coupled to the at least one processor;

wherein the memory stores instructions executable by the at least one processor, the at least one processor implements the aforementioned method by executing the instructions stored by the memory.

In another aspect, an embodiment of the present invention provides a construction machine, where the construction machine has the electronic device.

In yet another aspect, an embodiment of the present invention provides a computer-readable storage medium storing computer instructions, which, when executed on a computer, cause the computer to perform the foregoing method.

According to the invention, whether the relevant actual detection value is expressed as the geometrical mapping characteristic between the corresponding operation parameters or not is used for establishing the correlation between the monitoring modules of each parameter in the control system corresponding to the sensor, so that the first-layer monitoring is formed, the first fault working condition caused by the conditions of element or sensor data and the like can be monitored, and various safety control failures caused by abnormal data in the system are avoided; on the basis of the first-layer monitoring, the situation that a first fault working condition does not exist is determined, the moment balance relation is judged by using an actual detection value in the second-layer monitoring process, the situation that a second fault working condition with overturning danger caused by the conditions of structural abnormality, counterweight or hoisting control abnormality and the like cannot be found in time can be avoided, a network type redundancy monitoring means and a system product which are in cross correlation with a multi-sensor detection point are realized, the faults and fault early warning can be determined in time and reliably, the hoisting operation is assisted to be accurately and efficiently executed, the safety margin after the faults of a detection element, a monitoring network or a system is improved, and the occurrence of overturning accidents is avoided as much as possible.

The method specifically constructs the correlation between the operation parameters related to the boom posture and the actual detection values, carries out correlation monitoring on the angle sensors on the main arm and the super-lifting mast, and can realize the identification of whether the boom posture monitoring has faults and simultaneously effectively realize the control of hoisting operation and/or counterweight movement of the hoisting equipment based on whether the actual detection values related to the angles show the geometric mapping characteristics between the corresponding operation parameters, such as summation of the geometric mapping characteristics into specified angles of 180 degrees and the like.

The invention specifically constructs the correlation of the operation parameters and the actual detection values related to the counterweight stroke, carries out correlation monitoring on the angle sensor of the counterweight adjusting mechanism and the sensor with the displacement measurement function, and can realize the identification of whether the counterweight movement monitoring of the counterweight adjusting mechanism has faults and simultaneously effectively realize the control of the hoisting operation and/or the counterweight movement of the hoisting equipment based on whether the displacement and the actual detection values which are in angle correlation are expressed as the geometrical mapping characteristics between the corresponding operation parameters, such as whether the displacement converted by the angle is approximately equal to the detected displacement.

The invention particularly constructs the correlation of the operation parameters related to the magnitude of the suspended load (the magnitude of the moment at the suspended load end and/or the magnitude of the suspended load weight) and the actual detection value, carries out the correlated monitoring of the tension sensor on the main arm of the arm support close to the suspended load end and the pressure sensor at the root of the main arm, if the magnitude of the suspended load converted by the tension force is approximately equal to the magnitude of the suspended load converted by the pressure force, the method realizes the identification of whether the monitoring of the magnitude of the suspended load on the main arm has faults and simultaneously effectively realizes the control of the hoisting operation of the hoisting equipment and/or the movement of the counterweight, and further, the method also carries out the correlation monitoring of the pressure sensor at the bottom of the rear stay bar of the super-hoisting mast and the tension sensor and the pressure sensor on the main arm, if the pressure grade on the rear stay bar is matched with the tension grade or the pressure grade on the main arm, the identification of whether a fault exists in hoisting load size monitoring is further realized, and meanwhile, the hoisting operation of the hoisting equipment and/or the control of the movement of the counterweight are/is effectively realized.

The invention specifically constructs the correlation of operation parameters and actual detection values related to the balance moment, carries out correlation monitoring on sensors (such as a tension sensor, a pressure sensor, an angle sensor and/or a displacement measurement operation sensor and the like) for detecting moment calculation parameters by taking the rotation center as a reference point, and realizes the identification of whether faults exist in the moment monitoring by taking the rotation center as the reference and the control of the hoisting operation and/or the movement of the balance weight at the same time if the calculated moment of a hoisting end and the moment of a balance weight end are approximately equal.

Additional features and advantages of embodiments of the invention will be set forth in the detailed description which follows.

Drawings

The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the embodiments of the invention without limiting the embodiments of the invention. In the drawings:

FIG. 1 is a schematic diagram of the main method steps of an embodiment of the present invention;

FIG. 2 is a schematic diagram of exemplary operational key parameter to sensor correspondence, in accordance with an embodiment of the present invention;

FIG. 3 is a mechanically exploded schematic view of an exemplary primary arm head of a lifting device in accordance with embodiments of the present invention;

FIG. 4 is a schematic diagram of an exemplary monitoring network architecture according to an embodiment of the present invention;

fig. 5 is a schematic monitoring flow diagram under an exemplary monitoring network architecture according to an embodiment of the present invention;

FIG. 6 is a schematic illustration of the position of exemplary crane structures relative to a crawler body in accordance with an embodiment of the present invention;

FIG. 7 is a schematic view of the installation locations of some of the sensors on the partially enlarged structure of the crane of FIG. 6 in accordance with an embodiment of the present invention;

FIG. 8 is a schematic illustration of the installation locations of still further sensors on a partially enlarged structure of the crane of FIG. 6 in accordance with an embodiment of the present invention;

FIG. 9 is a partially enlarged schematic view of the locations of the sensors of FIG. 6 according to an embodiment of the present invention.

Detailed Description

The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating embodiments of the invention, are given by way of illustration and explanation only, not limitation.

Example 1

An embodiment of the present invention provides a fault double-layer redundancy monitoring method, as shown in fig. 1, the fault double-layer redundancy monitoring method may include:

based on the sensor groups correspondingly grouped according to the operation parameters on the hoisting equipment, obtaining sensor data of each operation parameter;

In some implementations, the hoisting device may include a crane, the crane may include a truck crane, an all-terrain crane, a crawler crane, etc., the hoisting device may be configured with a plurality of sensors, the sensors may be grouped and may be grouped according to a work critical parameter, i.e., the same work critical parameter is monitored by a plurality of sensors at the same time, and the work critical parameter may include a work parameter related to boom attitude, a work parameter related to counterweight travel, and a work parameter related to load size.

The operation parameters can be parameters directly measured by a sensor in the hoisting operation, the hoisting equipment can be provided with a control system, the control system can determine actual detection values of the operation parameters respectively measured by the sensor, the operation parameters can comprise the elevation angles of all arms or rods of an arm support of the hoisting equipment, the measured pressure on the arm support, the measured tension, the counterweight stroke and the like, and the actual detection values of the operation parameters can be used as sensor data; according to the arrangement position of the sensors on the hoisting equipment, the structural characteristics of the hoisting equipment, the safety operation requirement and the like, the geometric conversion relation among some operation parameters can be determined.

In the hoisting operation, in the first layer monitoring process, whether the relevant actual detection value corresponding to the operation parameter having the geometric conversion relation satisfies the conversion relation or not can be based on. For the judgment whether the actual detection value meets the conversion relation, the return of the judgment can be determined to be yes, namely the conversion relation is met, and meanwhile, the hoisting equipment can be determined to be in the working condition with normal monitoring function, namely not in the first fault working condition; or whether the judgment is returned or not can be determined, namely the conversion relation is not met, and meanwhile, the hoisting equipment can be determined to be in the first fault working condition, so that the judgment operation realized by combining the actual detection value with the correlation in the sensor data with the conversion relation of the operation parameters plays a role in fault monitoring. It should be added that, in some embodiments, the first fault condition may be implemented by a state identifier monitored by the first layer, and the state identifier may be configured to correspond to some default faults, or specific faults that may be finally determined according to the troubleshooting result, or may be caused by multiple faults, or may be designated as an indeterminate fault and to be troubleshot. For example, the first fault condition may include a sensor fault condition, an abnormal condition of a monitoring function due to inaccurate sensor data, an abnormal condition caused by sudden change of a working environment and/or an abnormal condition of an equipment structure, and the like, so as to implement a specific type of early warning and troubleshooting operation.

Specifically, the related actual detection values may include a first actual detection value and a second actual detection value, where the first actual detection value and the second actual detection value may both be one actual detection value, and the first actual detection value and/or the second actual detection value may also be a plurality of actual detection values, and there is at least a geometric conversion relationship between the operation parameter corresponding to the first actual detection value and the operation parameter corresponding to the second actual detection value. At this time, determining whether the hoisting device is in the first fault condition based on whether the actual detection value related to the sensor data satisfies the configured conversion relationship may specifically include: a converted detection value obtained by converting the first actual detection value in the sensor data in a configured conversion relationship is determined, and whether the converted detection value is the same as the second actual detection value in the sensor data or whether the converted detection value belongs to a specified numerical range corresponding to the second actual detection value is judged.

It can be understood that the conversion relationship may also include the specific equality or inequality both sides plus or minus the first actual detection value or the second actual detection value equality sub-transformation and the appropriate transformation using other values, which can be implemented to adapt to the specific program judgment mode and design requirements; in addition, since the actual detection values measured by the sensors may correspond to vector operation parameters, such as physical quantities having directions, such as displacement, acting force, moment, and the like, the conversion relationship may further include a vector conversion relationship and/or a structural mechanical conversion relationship, and the like, and in some actual data processing, the vector conversion relationship and/or the structural mechanical conversion relationship may be regarded as or processed into a geometric conversion relationship; it should be noted that the conversion relationship may not be reconfigured during the monitoring process, and the aforementioned determination performed based on the actual detection value may be performed cyclically.

In the second layer monitoring process, on the basis of the first layer monitoring, it is determined that the hoisting equipment is not in the first fault working condition, and whether the absolute value of the difference between the moment of the hoisting end and the moment of the counterweight end belongs to a specified numerical range corresponding to the moment balance state of the hoisting equipment or not can be specifically judged so as to determine that the hoisting equipment is in the second fault working condition; it should be added that, in some embodiments, the second fault condition may be implemented by a state identifier monitored by the second layer, which may be different from the state identifier monitored by the first layer, and also similarly, may be configured to correspond to some default faults, or specific faults finally determined according to the troubleshooting result, or may be caused by multiple faults, or may be designated as an indeterminate fault and to be troubleshot. For example, the second fault condition may include a counterweight control or suspension control abnormal condition, an operation non-standard condition, a control function abnormal condition, an abnormal condition caused by sudden change of an operation environment, and/or an equipment structure abnormal condition, so as to implement a specific type of early warning and troubleshooting operation.

In some specific implementations disclosed in the present invention, as shown in fig. 2, in the embodiments of the present invention, the correlated monitoring of the hoisting equipment is performed respectively for key monitoring parameters (or operation key parameters) such as boom attitude, counterweight travel, and hoisting load size, and in some cases, a multi-layer monitoring network may be formed.

In a first exemplary first layer monitoring embodiment, for monitoring the boom attitude, the hoisting device may have a super-lift mechanism, and the sensor data of the operation parameter related to the boom attitude may be obtained by an angle sensor (angle sensor for monitoring the angle, or any one of detection elements for tilt measurement, such as a rotation angle sensor and an encoder, which may convert an angular displacement and a linear displacement into an electrical signal) disposed at equal positions between the root and the head of the main boom (boom), the head and the root of the super-lift mast, and the main boom and the super-lift mast, and the sensor data may include actual detection values related to angles, and the operation parameter related to the boom attitude corresponding to the actual detection values related to angles may include a first elevation angle θ of the main boom of the hoisting device₁Second elevation angle theta of super-lifting mast of super-lifting mechanism₂And the included angle theta between the main arm and the super-lifting mast₃。

First, the actual detection values of the first elevation angle obtained at the root and the head of the main arm, respectively, and the actual detection values of the second elevation angle obtained at the head and the root of the super-lift mast, respectively, may be compared, and if the comparison is made, the actual detection values of the first elevation angle and the second elevation angle are obtainedIf the difference between the actual detection values does not exceed a predetermined value range (in this case, the difference may be not greater than a predetermined angle threshold, for example, but not limited to, not greater than 1 °), the average or any one of the actual detection values at the first elevation angle obtained at the root and the head of the main arm may be used as the first elevation angle θ of the main arm₁The actual detection value of (2) can also obtain the second elevation angle theta of the super-lift mast₂Is detected.

Second, the conversion relationship may be that the sum of the first elevation angle, the second elevation angle, and the angle is 180 degrees (°), written as:

θ₁+θ₂+θ₃＝180° (1)

in the formula (1), the actual detection value corresponding to one of the three operation parameters may be a first actual detection value, and the actual detection values corresponding to the other two operation parameters may be a second actual detection value, which may be determined by summing the three actual detection values, or by taking the difference between 180 degrees and the first actual detection value as the second actual detection value. In some actual data processing, a sensor error amount δ of the arranged angle sensors may be determined, which error amount δ may include an average error, a weighted average error, etc. of the respective angle sensors, and equation (1) may be further written as:

180°-δ≤θ₁+θ₂+θ₃≤180°+δ (2)

in equation (2), the error amount δ may also be initialized to a specified value, and adjusted and determined in combination with the performance in the actual hoisting device, and may be written as:

180°-δ₁≤θ₁+θ₂+θ₃≤180°+δ₂ (3)

in the equation (3), the adjusted error amount may include an error amount δ₁Sum error amount delta₂The absolute values of the two error amounts may not be equal.

Based on the monitoring manner at this time, the monitoring of the boom pose may form a current first-layer monitoring (network or system function layer), the first-layer monitoring network may include a two-layer monitoring sub-network (or system sub-function layer), the two-layer monitoring sub-network should be understood as a monitoring sub-network having at least two layers, and terms of two layers at any position in the embodiment of the present invention may be specific definitions of at least two layers, which may be understood in the embodiment of the present invention. In the first layer of monitoring the network,

the first-layer monitoring sub-network may be a monitoring sub-network that compares whether actual detection values of a plurality of sensors for the same operation parameter are too different, for example, whether actual detection values obtained at positions of the sensors at the elevation angle or the included angle are too different, and whether actual detection values obtained at positions of the sensors exceed a specified angle threshold may be regarded as being too different;

the second layer monitoring subnetwork may be the actual detection value related to the aforementioned determination and the first elevation angle theta₁A second elevation angle theta₂And angle theta₃The sum of the corresponding actual detection values falls within a prescribed numerical range ([180 ° - δ,180 ° + δ)]Or [180 ° - δ ]₁,180°+δ₂]) (i.e., whether the configured scaling relationship is satisfied); the conversion relationship at this time may be considered to include geometric conversion of the actually detected values of the operation parameters and the equation transformation.

If the difference of actual detection values does not exceed a specified angle threshold value by comparison of a first-layer monitoring sub-network in the first-layer monitoring network, the fact that each actual detection value is available and accurate can be temporarily considered, then, the judgment of a second-layer monitoring sub-network in the first-layer monitoring network returns to belong to a specified numerical range (namely, the conversion relation of configuration is met, and the return is yes), the fact that the sensor data is not abnormal and the monitoring function of the hoisting equipment is normal can be considered, and the hoisting equipment is determined not to be in a first fault working condition; if the first tier monitoring sub-network compares that the difference in actual sensed values does not exceed the specified angular threshold, then the actual sensed values may be temporarily deemed available and accurate. Then, if the judgment of the second-layer monitoring sub-network returns that the judgment exceeds the specified numerical range (namely the conversion relation of the configuration is not met, and the return is no), the data is considered to have errors due to faults of a sensor or an equipment structure and the like, the hoisting operation needs to be stopped, fault troubleshooting is carried out, and the hoisting equipment is determined to be in a first fault working condition; if the difference of the actual detection values does not exceed the specified angle threshold value in comparison with the first-layer monitoring sub-network, the situation that equipment fails or the operation of hoisting operation does not meet the requirement of safe operation can be considered, the hoisting equipment is determined to be in the first failure working condition, the hoisting operation needs to be stopped, and troubleshooting is carried out. In some cases, it may also be further determined, in combination with the return of no from the second monitoring layer, that the hoisting device has a monitoring function abnormality or other abnormality caused by the non-normative operation and equipment.

In a second exemplary first layer monitoring embodiment, for monitoring of a counterweight stroke, the lifting apparatus may have a movable counterweight adjustment mechanism, the counterweight adjustment mechanism may have a counterweight support arm and a counterweight adjustment mechanism, in some cases, the counterweight may be suspended by the counterweight support arm, the counterweight adjustment mechanism may have an oil cylinder, the oil cylinder may be driven by the control system to push the counterweight, if the counterweight is pushed in a horizontal direction, the counterweight may be pushed outward (away) or pushed inward (close) relative to the lifting apparatus, the counterweight stroke may be monitored in real time by a length sensor or a displacement sensor configured at a counterweight base on the counterweight adjustment mechanism, or the counterweight stroke may be estimated by the oil cylinder stroke to be monitored in real time, meanwhile, an angle sensor may be disposed at a root of the counterweight support arm, a third elevation angle (which may be an angle between the counterweight support arm and a projection in a displacement direction of the counterweight) of the counterweight support arm and a real-time counterweight measured by the counterweight adjustment mechanism The stroke may be regarded as an operation parameter related to a stroke of the counterweight, and the sensor data acquired at this time includes a stroke-related actual detection value, and a real-time stroke and a third elevation angle of the counterweight corresponding to the stroke-related actual detection value, respectively, where the stroke may be regarded as a movement distance or displacement of the counterweight from a pre-adjustment position to an post-adjustment position, instead of a maximum movement distance or displacement, in an embodiment of the present invention, and may be understood as such.

First, the counterweight real-time travel may be monitored using a length sensor, a displacement sensor (which may illustratively be mounted in a location near the length sensor), and a ram travel multiple sensors, and the third elevation angle may also be monitored using multiple angle sensors. And comparing whether the difference of the plurality of actual detection values of the real-time stroke of the counterweight exceeds a specified numerical range or not and comparing whether the difference of the plurality of actual detection values of the third elevation angle exceeds the specified numerical range or not. If the difference of the actual detection values obtained by the comparison does not exceed the specified numerical range, the average value of the actual detection values of the real-time stroke of the counterweight or any one of the actual detection values can be used as the actual detection value of the real-time stroke of the counterweight, and similarly, the actual detection value of the third elevation angle can also be obtained.

Secondly, the real-time stroke of the counterweight can be made to be L₁And a counterweight conversion stroke L obtained by calculating the third elevation angle theta₂Such as L₂F (theta), f can be a trigonometric function, and the real-time stroke L of the counterweight can be judged₁And the counterweight conversion stroke L₂Whether or not they are approximately equal, i.e.:

|L₁-L₂|≤ε₁ (4)

in the formula (4), epsilon₁Is a very small number, and can be specified based on the error of the sensor used₁And the size of [0, epsilon ] is adjusted adaptively according to the actual use performance₁]The current designated value range can be considered as the conversion relationship in this case, which includes both geometric conversion of the actual detected value of the operation parameter and comparison of the difference between the converted detected value and the actual detected value of the operation parameter.

Based on the monitoring mode at this time, the monitoring of the stroke of the counterweight can form a current first-layer monitoring network in which,

the first monitoring sub-network may be a monitoring sub-network that compares whether the actual measurements of the sensors for the same operating parameter differ too much, such as whether the actual measurements of the real-time travel of the counterweight differ more than a specified range of values, which in this case may be a specified travel threshold,

the second-tier monitoring sub-network may be a counterweight conversion stroke L obtained by converting an actual detection value corresponding to the third elevation angle θ among the actual detection values related to the determination₂The corresponding conversion detection value is compared with the real-time stroke L of the counterweight₁There is an approximate equality of the corresponding actual detection values.

Monitoring a first layer in a network if the first layer monitors a firstThe layer monitoring sub-network compares that the difference between the actual detection values of the real-time stroke and the third elevation angle of the counterweight does not exceed the specified stroke threshold, and the actual detection values can be temporarily considered to be available and accurate. Then, if the judgment of the second layer monitoring sub-network in the first layer monitoring network returns to the real-time stroke L of the counterweight₁And the counterweight conversion stroke L₂If the absolute value difference does not belong to the specified numerical range (namely, the absolute value difference is not approximately equal and does not satisfy the configured conversion relation), the data is considered to have errors due to the existence of faults such as sensors or equipment structures, the hoisting equipment is determined to be in the first fault working condition, the hoisting operation needs to be stopped, and the faults are checked. In other cases, the combination of the returned results of each monitoring layer and the corresponding device operation can be determined by continuing to refer to the monitoring of the boom posture, and details are not repeated.

In the third exemplary first layer monitoring embodiment, for monitoring the magnitude of the suspended load (including the magnitude of the suspended load moment and/or the magnitude of the suspended load weight), taking the suspended load weight as an example, on the one hand, a tension sensor may be disposed at a position, close to the head of the main arm, of a main arm drawplate of the hoisting device, and the suspended load weight may be calculated through a measured tension of the tension sensor, on the other hand, a pressure sensor may be disposed at the root of the main arm of the hoisting device, and the suspended load weight may also be calculated through a first measured pressure of the pressure sensor, and the operation parameters related to the magnitude of the suspended load may include the measured tension and the first measured pressure, and the sensor data may include an actual detected value related to the acting force.

First, actual detection values of the measured tension and the first measured pressure may be obtained using a plurality of sensors, respectively. Comparing a plurality of actual detection values of the measured tension and comparing a plurality of actual detection values of the first measured pressure. If the difference of the actual detection values obtained by the comparison does not exceed the specified numerical range, the average value of the actual detection values of the measured tension or any one of the actual detection values can be used as the actual detection value of the measured tension, and similarly, the actual detection value of the first measured pressure can also be obtained.

Secondly, based on the structural characteristics and sensor placement of the specific lifting device, as shown in FIG. 3, the suspended weight G can be weightedChemical decomposition, the two component forces are respectively the measuring tension G_laAnd a first measured pressure G_yaThe angle α is converted to the elevation angle through the main arm (e.g., the first elevation angle θ mentioned above)₁) The converted angle β can be calculated according to the length of the jib, the length of the super-lift mast, and the included angle between the jib and the super-lift mast (e.g., the included angle θ mentioned above)₃) Obtained in conjunction with the cosine theorem or a suitable trigonometric function calculation, can be written as:

G_la*sinβ/sinα＝G|_x＝la (5)

G_ya*sinβ/sin(α+β)＝G|_x＝ya (6)

in the equations (5) and (6), two conversion parameters of the suspended load G are the first suspended load G_x＝laAnd a second suspended weight G-_x＝yaThe trigonometric function relationship or force conversion coefficient used is not a limiting embodiment, and may be implemented based on adaptation such as a mechanical decomposition method, a sensor arrangement position, and the like, and may be written as:

G_x0*Tr_x0＝G|_x＝x0 (7)

in formula (7), G-_x＝x0Can represent the weight component G of the suspended load_x0Conversion parameter, Tr, of corresponding suspended load G_x0Representing the weight component G of the suspended load_x0Force conversion coefficient or trigonometric function relationship of; based on the actual detection values of the measured tension and the first measured pressure, the calculated angles alpha and beta are combined to respectively determine the first suspended load weight G_x＝laAnd a second suspended weight G-_x＝yaThen the first suspended weight G & lt & gtcalculation detection value can be judged_x＝laAnd a second suspended weight G-_x＝yaWhether the converted detection value falls within a specified value range epsilon₂(i.e., whether approximately equal) can be written as:

|G|_x＝la-G|_x＝ya|≤ε₂ (8)

in formula (8), ε₂Is a very small number, and can be specified based on the error of the sensor used₂And the size of [0, epsilon ] is adjusted adaptively according to the actual use performance₂]Can be used as the current designated numerical range, and the conversion relation in the time can be regarded asThe method comprises mechanical conversion or geometric conversion of the actual detection value of the operation parameter, and also comprises difference comparison of a plurality of converted detection values of the same target operation parameter.

Based on the monitoring mode at this time, the monitoring of the magnitude of the suspended load can form a current first-layer monitoring network in which,

the first monitoring sub-network may be a monitoring sub-network that compares actual measurements from a plurality of sensors for the same operating parameter with respect to one another to determine if the difference between the actual measurements exceeds a specified value, which may be a force threshold,

the second layer monitoring sub-network may judge whether or not there is an approximate equality between converted detection values obtained by converting actual detection values corresponding to the measured tension and the first measured pressure among the related actual detection values;

if the first-layer monitoring sub-network in the first-layer monitoring network does not obtain the actual detection values of the measured tension and the first measured pressure exceeding the specified action force threshold value, the actual detection values can be temporarily considered to be available and accurate. Then, if the second layer monitoring sub-network in the first layer monitoring network judges the first suspended weight G_x＝laAnd a second suspended weight G-_x＝yaIf the difference between the absolute values of the two-dimensional data is not within the specified numerical range (namely, the absolute values are not approximately equal and do not satisfy the configured conversion relation), the data is considered to have errors due to the existence of faults such as sensors or equipment structures, and the hoisting operation needs to be stopped and troubleshooting is performed if the hoisting equipment is determined to be in the first fault condition. In other cases, the combination of the returned results of each monitoring layer and the corresponding device operation can be determined by continuing to refer to the monitoring of the boom posture, and details are not repeated.

The hoisting load size is a very important parameter in hoisting operation executed by the hoisting equipment, and aiming at monitoring the hoisting load size, a pressure sensor can be arranged at the bottom of the rear support rod of the super-lifting mast, a second measurement pressure can be determined through the pressure sensor, an intermediate layer monitoring network can be formed based on the second measurement pressure, and the intermediate layer monitoring network can be a monitoring network between a first layer monitoring network and a second layer monitoring network, so that the embodiment of the invention further provides a three-layer monitoring network.

In an embodiment of the intermediate level monitoring network, at least three levels of the third payload (which can be regarded as a reduced variable of the payload G) can be determined by means of the second measured pressure on the basis of at least two pressure reference values, for example the second measured pressure F_pReference value of pressure F₁And F₂(F_p≤F₁,F₁<F_p≤F₂,F₂<F_pRespectively corresponding to the magnitude levels of the third suspended load weight being small, medium, and large), the current magnitude level of the third suspended load weight may be determined based on the actual detected value of the second measured pressure, and the suspended load weight G may be regarded (may be determined to be approximately equal after the converted detected value corresponding to the suspended load weight G is determined to be approximately equal) as the first suspended load weight G_x＝laAnd a second suspended weight G-_x＝yaEither of which may also be based on at least two weight references, such as weight reference G₁And G₂(G≤G₁,G₁<G≤G₂,G₂<G is respectively corresponding to small, medium and large grades), determining the current size grade of the suspended load G, such as large, medium and small, then determining the size grade matching relationship between the current size grade of the suspended load G and the current size grade of the third suspended load, and judging whether the size grade matching relationship is the matching relationship corresponding to the stable state of the hoisting equipment, wherein the stable state of the hoisting equipment comprises a stable state and an unstable state, and the unstable state comprises a forward (main arm position is regarded as forward) tilting state and a backward tilting state; when the current magnitude grade of the hoisting weight G is large, the hoisting equipment is in a forward tilting state, and the magnitude grade matched with the current magnitude grade of the third hoisting weight is small; when the current size grade of the hoisting weight G is middle, the hoisting equipment is in a stable state, and the size grade matched with the current size grade of the third hoisting weight is also middle; when the current magnitude level of the suspended load G is small, the hoisting apparatus is in a tilted-back state, and the magnitude level to which the current magnitude level of the third suspended load should be matched is large. Need to explainThe stable state of the hoisting equipment can be determined based on the applied counterweight moving operation, the hoisting operation stage and the like, and if the hoisted object is delivered or the hoisted object is light, the stable state can be a backward tilting state at the moment if the counterweight is suspended.

In some data processing implementations, the third sling weight is recorded as G_pThe large, medium and small grades are respectively marked as 1, 0 and-1, and the large and small grades S of the suspended load G at each time i (which may be a positive integer) of the suspending operation are set to { S ═ S {_iAnd a third suspended load G_pThe magnitude grade V of each hoisting operation time i is ═ V_iThe matching relationship corresponding to the steady state of the hoisting device can be written as:

TABLE 1 theoretical size class matching relationship table

s_i	1	0	-1
				v_i	-1	0	1

For judging whether the size grade matching relation corresponding to the related actual detection value is the matching relation corresponding to the steady state of the hoisting equipment or not, the column vector can be usedElements anda determination is made as to whether 0 is present, written as:

s_i+v_i＝0 (9)

if the formula (9) does not hold, it can be determined that the hoisting equipment is in a fault working condition, at least the monitoring function of the operation parameters is abnormal, the hoisting operation needs to be stopped, and the fault is eliminated.

Based on the monitoring mode at this time, the middle layer monitoring network may also have a double-layer monitoring sub-network. The middle layer monitors the network in which,

the first-layer monitoring sub-network may be a monitoring sub-network that compares whether actual detection values of a plurality of sensors for the same job parameter are excessively different, such as whether a difference in a plurality of actual detection values of a second measured pressure that can be obtained by a plurality of pressure sensors exceeds a specified numerical range;

the second layer monitoring sub-network may be the actual measurement value associated with the second measured pressure F_pThird suspended load weight G converted from corresponding actual detection value_pWhether the magnitude level of (a) is a matching relation with the magnitude level of the hoisting weight G or not is a matching relation corresponding to the steady state of the hoisting equipment, such as through a column vectorElement and whether it is actually 0.

When the hoisting equipment is not in the first fault working condition, the middle layer monitoring network can be used for judging the first layer monitoring network, and after the middle layer monitoring network judges that the hoisting equipment is not in the third fault working condition, the subsequent second layer monitoring network can be judged.

If the first layer monitoring subnetwork in the middle layer monitoring network compares that the difference of a plurality of actual detection values of the second measured pressure, which are not obtained, exceeds a specified value range, the actual detection values can be temporarily considered to be available and accurate. Then, if a second monitoring subnetwork in the intermediate monitoring network can determine the second measured pressure F from the relevant actual measured values_pThird suspended load weight converted from corresponding actual detection valueG_pIf the magnitude grade of the hoisting load G is not the matching relation corresponding to the steady state of the hoisting equipment, the hoisting equipment is determined to be in the third fault working condition, the hoisting operation needs to be stopped, and the examination is carried out. It will be appreciated that the third fault condition may be implemented by a state indicator monitored by the intermediate layer, which may be different from the state indicators monitored by the first and second layers, and may similarly be configured to correspond to default faults, or specific faults that may be finally determined according to the troubleshooting results, or may be caused by multiple faults, or may be designated as indeterminate faults and to be troubleshot. For example, the third fault condition may include a hoisting balance abnormal condition, an operation non-standard condition, a control function abnormal condition, an abnormal condition caused by sudden change of an operation environment, and/or an equipment structure abnormal condition, so as to implement a specific type of early warning and troubleshooting operation.

It should be additionally added that, based on the above monitoring implementation, in some embodiments, the first-layer monitoring network may have at least one of the foregoing boom posture monitoring, counterweight travel monitoring, and suspended load size monitoring, and any one of the first-layer monitoring sub-networks in the first-layer monitoring network may be selected according to actual needs, and the second-layer monitoring sub-network in the first-layer monitoring network may be a main part of the first-layer monitoring network. The first layer monitoring sub-network in the middle layer monitoring network can be selected according to actual requirements, and the second layer monitoring sub-network in the middle layer monitoring network can also be used as a main part of the middle layer monitoring network.

In the process of monitoring the magnitude of the suspended load, the actual detection values of some operation parameters in the monitoring of the boom attitude are correlated, in an advantageous implementation, the operation parameters in the monitoring of the boom attitude, the monitoring of the counterweight stroke and the monitoring of the magnitude of the suspended load can be correlated, the actual detection values of all the operation parameters are correlated, and the monitoring of the actual detection values corresponding to the moment in the second-layer monitoring network can be realized specifically through judgment of the moment balance of the operation parameters of the suspended load end and the counterweight end.

In an exemplary second-layer monitoring embodiment, based on a slewing support center of a hoisting device, a hoisting end moment and a counterweight end moment are calculated, whether moment balance is met is judged, and correlation monitoring is achieved. Calculating the moment M of the hoisting end_{Suspended load}：

M_{Suspended load}＝m₁(G,Θ) (10)

In the formula (10), m₁And (G, theta) is a moment calculation function about the hoisting load size G and the boom attitude theta (such as elevation angle and the like) based on the structural characteristics of specific hoisting equipment and the arrangement position configuration of the sensor. Similarly, the moment M at the counterweight end is calculated_{Counterweight}：

M_{Counterweight}＝m₂(L) (11)

In formula (11), m₂And (L) is a moment calculation function related to the counterweight travel L and configured based on the specific hoisting equipment structural characteristics and the sensor arrangement position. In the hoisting process, the crane can verify the moment balance state of the hoisting equipment according to the field condition, and if the moment balance state is balanced, the moment balance relation is satisfied:

M_{suspended load}＝M_{Counterweight} (12)

From the formula (12), the internal moment balance relationship of the operation parameters in the monitoring of the boom posture, the counterweight stroke and the hoisting load size can be determined; a certain error range can be set, and whether the actual detection values of the operation parameters in the three monitoring sub-networks show faults or not can be judged according to a moment balance equation, namely whether the difference between the absolute values of the moment of the suspended load end and the moment of the counterweight end belongs to a specified numerical range or not is judged, and the following steps are written as follows:

|M_{suspended load}-M_{Counterweight}|≤ε₃ (13)

In formula (13), ε₃Is a very small number, can specify ε₃And the size of [0, epsilon ] is adjusted adaptively according to the actual use performance₃]The current specified numerical range can be used, if the formula (13) does not hold, it is determined that the hoisting equipment is in the second fault working condition, moment imbalance occurs, an error occurs in operation parameter monitoring, and fault troubleshooting should be performed.

Based on the monitoring mode at this time, the moment balance monitoring can form a second-layer monitoring network, and the second-layer monitoring network can be used for judging the hoisting end moment M calculated on the basis of the actual detection value corresponding to the hoisting size G and the boom posture theta in the relevant actual detection values_{Suspended load}And a counterweight end moment M calculated based on an actual detection value corresponding to the counterweight stroke L_{Counterweight}If the absolute value difference of the converted detection values does not belong to the specified numerical range (namely, the absolute value difference is not approximately equal), the hoisting equipment is determined to be in a second fault working condition, and the hoisting operation needs to be stopped and the fault is checked if the data is wrong due to the existence of faults of a sensor or an equipment structure and the like; the second layer monitoring network, the first layer monitoring network and the middle layer monitoring network form a multi-layer monitoring network (or a monitoring system) of the hoisting equipment. In some cases, the second monitoring network may have a dual-layer monitoring sub-network, and similarly, the first monitoring sub-network is used for determining the difference of the actual detection values of the plurality of sensors, and the second monitoring sub-network is used for determining whether the actual detection values meet the moment balance relationship.

In an exemplary disclosed implementation of the embodiment of the present invention, as shown in fig. 4, the monitoring network of the hoisting equipment may include an acquisition layer 100, a first layer monitoring network composed of a boom posture monitoring network 200, a counterweight stroke monitoring network 300, and a sling size monitoring network 400, a second layer monitoring network 500, and a fault output layer 600, where the fault output layer 600 may output a state identifier of a first fault state and a state identifier of a second fault state, the acquisition layer 100 is configured to acquire sensor data of each operation parameter of the hoisting equipment, and relevant actual detection values in the sensor data include an actual detection value corresponding to an operation parameter 101 related to a boom posture, an actual detection value corresponding to an operation parameter 102 related to a counterweight stroke, and an actual detection value corresponding to an operation parameter 103 related to a sling size; the boom attitude monitoring network 200 comprises a first-layer monitoring sub-network 204 and a second-layer monitoring sub-network 205, the first-layer monitoring sub-network 204 and the second-layer monitoring sub-network 205 can perform data synchronous receiving operations 201 and 202, the second-layer monitoring sub-network 205 can also perform data receiving operation 206 asynchronously after the first-layer monitoring sub-network 204 outputs a judgment result 208 to a fault output layer 600, and both the judgment results 207 and 208 can be used for determining whether hoisting equipment is in a first fault condition; the counterweight stroke monitoring network 300 and the sling size monitoring network 400 can also be formed by similar double-layer monitoring sub-network structures (sub-networks 301 and 302 and sub-networks 401 and 402), and the working mechanisms of the counterweight stroke monitoring network 300 and the sling size monitoring network 400 can refer to the boom posture monitoring network 200 and are not repeated. The second-layer monitoring network 500 may perform data synchronous receiving operations 203, 303, and 403 corresponding to each of the two-layer monitoring subnetworks, and the second-layer monitoring network 500 may also output a return result 501 of the determination to the fault output layer 600, where the second-layer monitoring network 500 may perform the determination again on the basis of the determination that the hoisting device is not in the first fault condition by the first-layer monitoring network; the fault output layer 600 is configured to determine whether any one of the judged returns is N and determine that the hoisting device is in the first fault condition or the second fault condition, and the fault output layer 600 may also be configured to output a result that each return is Y, that is, the hoisting device is not in the first fault condition or the second fault condition. In the monitoring network of the hoisting equipment, an intermediate layer monitoring network (not shown in fig. 4) may be further configured, where the intermediate layer monitoring network may receive data from the acquisition layer 100, and determine whether the hoisting equipment is in a third failure condition based on the determination that the hoisting equipment is not in the first failure condition by the first layer monitoring network and the determination that the second layer monitoring network is not performed, and output a result of the determination by the intermediate layer monitoring network to the failure output layer 600.

As shown in fig. 5, the fault dual-layer redundancy monitoring method may specifically include:

s1) receiving sensor data transmitted by the acquisition layer 100 through the first layer monitoring network, specifically, the boom posture monitoring network 200, the counterweight travel monitoring network 300, and the lifting load size monitoring network 400 receive sensor data transmitted by the acquisition layer 100;

s2) determining whether the sensor data conforms to the conversion relationship through the first layer monitoring network, specifically, determining whether the sensor data conforms to the conversion relationship through at least one of the boom posture monitoring network 200, the counterweight travel monitoring network 300 and the lifting load size monitoring network 400 based on the sensor data, and determining whether the hoisting equipment is in a first fault condition;

s3) determining whether the sensor data conforms to the moment balance relationship via the second layer monitoring network 500, and determining whether the hoisting device is in the second fault condition, at which time the hoisting device is determined not to be in the first fault condition. In this case, the sensor data may be transmitted to the dual-layer monitoring network synchronously or asynchronously, and in some cases, the sensor data received by the second-layer monitoring network may also be forwarded by the first-layer monitoring network.

In a further embodiment, the fault dual-layer redundancy monitoring method may further specifically include: after the hoisting equipment is determined not to be in the first fault working condition, whether the sensor data meet the size grade matching relation or not is judged through the middle layer monitoring network, and whether the hoisting equipment is in the third fault working condition or not is determined.

In a further embodiment, the fault dual-layer redundancy monitoring method may further specifically include: after the hoisting equipment is determined not to be in the second fault working condition and the third fault working condition, the movement of the counterweight and the execution of hoisting operation can be controlled in real time by using the data of the sensor at the moment.

The embodiment of the invention also provides a fault double-layer redundancy early warning method, which comprises the fault double-layer redundancy monitoring method, and the fault double-layer redundancy early warning method can also comprise the following steps:

s1') determining that the hoisting equipment is in any fault condition;

s2') stopping the hoisting device from performing the hoisting operation and performing the pre-warning of the configuration.

In some implementations, the configured pre-warning may include performing an operation screen prompt and broadcast of the hoisting device, performing an audible and visual alarm, performing troubleshooting, and the like.

Compare in the fixed counter weight of tradition, the portable counter weight can enlarge the lifting capacity under the equal counter weight big or small condition of hoist, if can adjust counter weight position in a flexible way keep the system focus in gyration support central point department then can improve hoist and mount stability, however, the counter weight is portable mostly need be based on the counter weight is unsettled, the counter weight is liftoff the back, the system only revolves and supports a fulcrum, the elevating load end all probably has the risk of tumbling with the counter weight end, in hoist and mount operation in-process, need change according to the elevating load and match suitable counter weight stroke in real time, the safety requirement that leads to overall control increases by a wide margin, safety monitoring's the degree of difficulty also promotes by a wide margin. In the embodiment of the invention, after the counterweight is suspended and movable, the reliable monitoring of the hoisting equipment is divided into a double-layer redundant monitoring network of a first-layer monitoring network and a second-layer monitoring network, the reliable and accurate monitoring of three operation key parameters in the first-layer monitoring network is mainly realized, the three operation key parameters are respectively the attitude of the arm support, the counterweight stroke and the suspended load size, whether a first fault working condition exists or not can be determined in real time according to the converted detection values or related actual detection values of the three operation key parameters, when the first fault working condition does not exist, the second-layer monitoring network can judge the moment balance, the moment balance state of the hoisting equipment can be calculated in real time, and the accurate counterweight stroke (counterweight matching or moving position) can be given in real time, so that whether the system operation working condition is in a safety control range or not can be judged according to the moment balance state, the usability and the accuracy of the control of the movement of the overhead counterweight and the suspension control can be guaranteed, so that the embodiment of the invention realizes a reliable safety redundancy monitoring scheme of the hoisting equipment aiming at the geometric conversion relation of the three key parameters and the moment balance relation of the operating parameters related to the moment, and particularly can improve the safety and stability performance of the dynamic variable stroke of the suspended counterweight of the crawler crane.

The embodiment of the invention can set a safety redundancy monitoring scheme of operation key parameters (boom posture, suspension load size and counterweight stroke) particularly for a novel crane of a crawler crane with a movable suspended counterweight, ensures the monitoring precision of the key parameters in the operation process, can be used for monitoring related faults of a system, increases the operation safety margin, improves the safety performance, realizes the relevance analysis of each monitoring parameter from the balance of the integral moment of the system, constructs a monitoring network of the integral system of the crane, and provides a novel system safety monitoring scheme for the development of the novel crane for lifting the counterweight without falling to the ground.

The embodiment of the invention can configure double-layer or three-layer safety redundant monitoring aiming at the same operation key parameter on the basis of the existing hardware monitoring network of the sensor of the hoisting equipment, thereby ensuring that the monitoring precision of each key parameter in the operation process meets the requirement of safety operation; the embodiment of the invention not only carries out redundancy monitoring on the operation parameters independently, but also establishes the correlation among the parameters according to the moment balance of the system, and gives out the judgment of the system-level monitoring precision to form a monitoring network.

The multilayer redundancy monitoring scheme of the embodiment of the invention can compare the difference of the obtained detection values in real time, and can judge that a fault occurs when the difference is larger than the allowable range of the safety error, suspend the operation of equipment and analyze the system fault; the redundancy monitoring scheme of the embodiment of the invention can be independently used as an independent monitoring system to respectively monitor three operation key parameters of the arm support posture, the hoisting load size and the counterweight stroke, thereby realizing a plurality of selectable hoisting equipment monitoring systems.

Example 2

The embodiment of the invention and the embodiment 1 belong to the same invention concept, the embodiment of the invention provides a fault double-layer redundancy early warning system, the fault double-layer redundancy early warning system is understood to be that the system has at least a double-layer monitoring module, and the fault double-layer redundancy early warning system can comprise:

This double-deck redundant early warning system of trouble still includes:

the early warning module is used for determining that the hoisting equipment is in any fault working condition, and

and stopping the hoisting equipment to execute hoisting operation and executing configuration early warning.

Specifically, the hoisting device is provided with a super-lifting mechanism, and the obtaining module is specifically used for obtaining sensor data of operation parameters related to the boom posture, wherein the sensor data comprises actual detection values related to the angle,

In particular, the hoisting device further has a movable counterweight adjustment mechanism, and the obtaining module is specifically configured to obtain sensor data of an operating parameter related to a counterweight stroke, wherein the sensor data includes an actual detection value related to the stroke,

In particular, the obtaining module is specifically configured to obtain sensor data of an operation parameter related to the magnitude of the suspended load, wherein the sensor data includes an actual detection value related to the acting force,

Specifically, the first layer monitoring module may have the same function as the first layer monitoring network in embodiment 1, and the second layer monitoring module may have the same function as the second layer monitoring network.

Specifically, the first layer monitoring module is specifically configured to:

determining a converted detection value obtained by converting the first actual detection value in the sensor data according to the configured conversion relation, and

judging whether the converted detection value is the same as a second actual detection value in the sensor data, or

Determining whether the scaled detection value falls within a specified range of values corresponding to the second actual detection value, wherein,

if the judged return is yes, determining that the hoisting equipment is not in a first fault working condition;

and if the judged return is negative, determining that the hoisting equipment is in the first fault working condition.

Specifically, the first layer monitoring module is configured to configure a conversion relationship that a sum of the first elevation angle, the second elevation angle, and the included angle is a specified angle or belongs to a specified numerical range corresponding to the specified angle.

Specifically, the first layer monitoring module is specifically configured to read actual detection values corresponding to the three in the sensor data;

the first-layer monitoring module is specifically configured to determine, according to a configured conversion relationship, whether a sum of actual detection values corresponding to the three is the specified angle or not, or whether the sum belongs to a specified numerical range corresponding to the specified angle.

Specifically, the first layer monitoring module, wherein the obtaining manner of the specified numerical range includes:

determining a sensor error amount of the arranged angle sensor;

configuring a numerical range of a first numerical value to a second numerical value to be a specified numerical range, wherein,

the first value is a difference between the specified angle and the sensor error amount,

the second value is a sum of the specified angle and the sensor error amount.

Specifically, the first layer monitoring module is configured to configure a conversion relationship that includes that an absolute value of a difference between a converted stroke of the counterweight obtained by the third elevation calculation and the real-time stroke of the counterweight belongs to a specified numerical range.

Specifically, the first layer monitoring module is specifically configured to read an actual detection value corresponding to the third elevation angle and the real-time counterweight travel in the sensor data, and determine a conversion detection value of the counterweight conversion travel according to the actual detection value corresponding to the third elevation angle;

the first-layer monitoring module is specifically configured to determine whether an absolute value of a difference between an actual detection value corresponding to the real-time counterweight travel and the converted detection value belongs to the specified numerical range according to a configured conversion relationship.

Specifically, the first floor monitoring module is configured such that the conversion relationship includes that an absolute value of a difference between the first suspended load weight and the second suspended load weight falls within a specified range of values,

the first suspended load weight is obtained by converting the measured tension through a first trigonometric function relation,

and the second suspended load weight is obtained by converting the first measured pressure through a second trigonometric function relation.

Specifically, the first layer monitoring module is specifically configured to read actual detection values corresponding to the measured tension and the first measured pressure in the sensor data, and determine converted detection values corresponding to the first suspended load weight and the second suspended load weight respectively;

the first floor monitoring module is specifically configured to determine, according to a configured conversion relationship, whether an absolute value of a difference between conversion detection values corresponding to the first suspended load weight and the second suspended load weight belongs to the specified numerical range.

Specifically, this redundant early warning system of trouble double-deck still includes:

the middle layer monitoring module is used for judging whether the size grade matching relation is the matching relation corresponding to the steady state of the hoisting equipment or not, wherein,

the magnitude grade of the third suspended load weight is obtained through the second measurement pressure.

Specifically, the middle layer monitoring module may have the same function as the middle layer monitoring network in the monitoring network of the hoisting device in embodiment 1.

Specifically, the second-layer monitoring module is configured to determine whether an absolute value of a difference between a moment at the hoisting end and a moment at the counterweight end belongs to a specified numerical range corresponding to a moment balance state of the hoisting apparatus, wherein,

the moment of the hoisting end is obtained by calculating an actual detection value related to an angle and an actual detection value related to an acting force,

the moment of the counterweight end is obtained by calculation of actual detection values which are stroke-related.

In some implementations, the fault dual-level redundancy early warning system (or the acquisition module and any at least one monitoring module therein) can be implemented based on hardware such as one or more controllers and/or an electronic device with a processor, and in some cases, the fault dual-level redundancy early warning system can be implemented in digital electronic circuitry, integrated circuitry, Field Programmable Gate Arrays (FPGAs), Application Specific Integrated Circuits (ASICs), Application Specific Standard Products (ASSPs), system on a chip (SoC), load programmable logic devices (CPLDs), computer hardware, firmware, software, and/or combinations thereof.

Example 3

The embodiment of the invention belongs to the same inventive concept as the embodiments 1 and 2, and provides electronic equipment, engineering machinery and a computer-readable storage medium.

Electronic devices are intended to mean all forms of devices having instruction processing and computing capabilities, such as computers, industrial computers, servers and the like, the processor and the memory being implemented in the form of a system-on-a-chip (SoC or MCU) or directly assembled using a circuit board having a connection interface. The memory stores instructions executable by the at least one processor, and the at least one processor implements the method of embodiment 1 by executing the instructions stored in the memory, and the electronic device may be used to form a monitoring network of the lifting device of embodiment 1, and in some advantageous embodiments, the electronic device and the sensor group may be used as entity devices of the monitoring network.

The engineering machine may have the aforementioned electronic equipment, and the engineering machine may include hoisting equipment including an automobile crane, an all-terrain crane, a crawler crane, and the like. In an exemplary advantageous disclosed embodiment of the present invention, a crawler crane, as shown in fig. 6, includes a crawler body, a main jib, a superlift mast, a (rear) stay, a cylinder for a counterweight-suspended adjustment arm, etc., and a counterweight of the crawler crane may be suspended above the ground. The crawler crane realizes the fault double-layer redundancy early warning system in the embodiment 2 through electronic equipment, and is subjected to multilayer monitoring network fault early warning. The crawler crane may be equipped with a sensor group. As shown in fig. 7, a main arm pulling plate (referred to as a pulling plate position region) pulling force sensor and a main arm head angle sensor are mounted on the main arm. As shown in fig. 8, an in-first position area angle sensor a and a in-second position area angle sensor B are mounted on the super lift mast. As shown in fig. 9, a cylinder stroke sensor for converting the stroke of the counterweight is mounted on the cylinder; on the counterweight support arm, an angle sensor is mounted, the preferred area where the angle sensor is mounted being shown in the top layer of the figure in fig. 9; a pressure sensor at the bottom of the brace rod (in the position area of the bottom of the brace rod) is arranged on the brace rod; an included angle sensor of the main arm and the super-lifting mast is arranged between the main arm and the super-lifting mast; the main arm is provided with an angle sensor and a pressure sensor at the root part of the main arm (in the position area of the root part); and the super-lifting mast root angle sensor is arranged on the super-lifting mast.

The computer-readable storage medium may be non-transitory and may be configured with a computer program that, when executed by a processor, implements the method of embodiment 1 described above, enabling fault monitoring of a hoisting device.

Although the embodiments of the present invention have been described in detail with reference to the accompanying drawings, the embodiments of the present invention are not limited to the details of the above embodiments, and various simple modifications can be made to the technical solutions of the embodiments of the present invention within the technical idea of the embodiments of the present invention, and the simple modifications all belong to the protection scope of the embodiments of the present invention.

It should be noted that the various features described in the above embodiments may be combined in any suitable manner without departing from the scope of the invention. In order to avoid unnecessary repetition, the embodiments of the present invention do not describe every possible combination.

Those skilled in the art will understand that all or part of the steps in the method according to the above embodiments may be implemented by a program, which is stored in a storage medium and includes several instructions to enable a single chip, a chip, or a processor (processor) to execute all or part of the steps in the method according to the embodiments of the present application. The monitoring network (or monitoring system) may be a sensor network or other device group for measuring, recording, analyzing and processing, and the monitoring network or monitoring system may include a plurality of hardware and/or software having sensing, data recording, data processing and so on functions. The aforementioned storage medium may be non-transitory, and the storage medium may include: a U-disk, a hard disk, a Read-Only Memory (ROM), a flash Memory (flash Memory), a magnetic disk, an optical disk, or other various media capable of storing program codes.

In addition, any combination of various different implementation manners of the embodiments of the present invention is also possible, and the embodiments of the present invention should be considered as disclosed in the embodiments of the present invention as long as the combination does not depart from the spirit of the embodiments of the present invention.

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Fault double-layer redundancy monitoring method, early warning method and system

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