WO2018152721A1 - On-line monitoring system and method for suspension steel wire rope for hoisting container - Google Patents

Abstract

An on-line monitoring system and method for a suspension steel wire rope for a hoisting container. The system comprises: a first sensing unit, a container top relay device, a wellhead receiving relay device, an analysis gateway, and a data display and analysis processing platform. The first sensing unit is used for real-time acquisition of a first state parameter capable of characterizing a suspension steel wire rope; the container top relay device is disposed at the top of a hoisting container and electrically connected to the first sensing unit, and is used for receiving the first state parameter acquired by the first sensing unit, and transmitting the first state parameter to the wellhead receiving relay device by means of frequency hopping and spreading and time division multiple access wireless technology; the wellhead receiving relay device is disposed on the inner wall of a shaft or at a wellhead and used for transmitting the received data to the data display and analysis processing platform by means of the analysis gateway to facilitate display, analysis, and processing of the data. The method can achieve real-time uninterrupted monitoring of a suspension steel wire rope for a hoisting container during periodic operation, and ensure the reliability and security of a hoisting system in a deep well environment.

Description

Lifting container hanging wire rope online monitoring system and method Technical field

The invention relates to the field of safety monitoring, in particular to an online monitoring system and method for lifting a suspension wire rope of a container in a deep well environment.

Background technique

In deep well environments (such as elevator shafts, mines, etc.), lifting mechanisms (such as elevator cars, cages, etc.) are typically driven up and down using a mating mechanism of rollers and suspended wire ropes. The monitoring of the state of use of the suspended wire rope is essential for the safe operation of the lifting vessel.

Existing suspension wire rope monitoring includes tension monitoring and lateral vibration signal monitoring. For example, in the Chinese utility model patent "A tension detecting device for an elevator wire rope" disclosed in CN203359719U, the end of each wire rope is provided with a tension detecting device for the elevator wire rope, by making the tension of each elevator wire rope The pre-pressure of the oil pressure sensor on the detecting device is uniform, so that the accuracy of the tensile force detection result of each wire rope is improved. However, such a device is only effective for an elevator wire rope. For a mine environment where the downhole distance is larger and a plurality of balance wire ropes are used, the tension detecting device has a large error. In addition, the program can only be used for monitoring and data collection of wire rope signals, and real-time monitoring is not possible.

In the Chinese invention patent application CN104203200A, the "wire rope transverse vibration signal measuring device, method and lateral vibration monitoring method", the monitoring scheme adopted is to measure the vibration displacement signal by using the wire rope lateral vibration displacement signal measuring method, and the vibration displacement is measured. The signal is processed to obtain the vibration amplitude and vibration frequency, and then compared with the preset value for crisis prevention. This solution can only monitor lateral vibration signals without considering the effects of longitudinal vibration on the lifting system.

In short, in the existing technical practice and theoretical research, the suspension wire rope monitoring with a mine depth of 500 m or less is generally applied, while the deep well research of 500 m or more is less. In the deep well environment of 500m or more, the signal transmission and penetration ability are weak, the energy loss is large, and the interference is large, which makes the real-time and accurate monitoring of the suspension wire rope difficult. On the other hand, the vast majority focus on the monitoring of unilateral factors and the lack of monitoring studies for a variety of factors.

Summary of the invention

The object of the present invention is to provide an on-line monitoring system and method for lifting a suspended wire rope of a container, which can realize real-time uninterrupted monitoring of the suspension wire rope of the lifting container during periodic operation, and ensure the reliability and safety of the lifting system in a deep well environment.

To achieve the above object, the present invention provides an on-line monitoring system for lifting a suspended wire of a container, comprising: a first sensing unit, a container top relay device, a wellhead receiving relay device, a resolution gateway, and a data display and analysis processing platform; The first sensing unit is configured to collect a first state parameter capable of characterizing the suspension wire rope in real time; the container top relay device is disposed at the top of the lifting container and electrically connected to the first sensing unit for receiving a first state parameter collected by the first sensing unit, and transmitting the first state parameter to the wellhead receiving relay device by frequency hopping spread spectrum and time division multiple access wireless technology; the wellhead receiving relay The device is disposed at the inner wall of the wellbore or the wellhead for transmitting the received data to the data display and analysis processing platform via the resolution gateway for display, analysis and processing of the data.

Further, data transmission is performed between the wellhead receiving relay device and the resolution gateway by using a frequency hopping communication method.

Further, the first sensing unit includes a plurality of oil pressure sensors respectively disposed on the wire rope tension hydraulic automatic balancing device on the top of the lifting container, corresponding to the bypass of the balancing oil cylinders of the respective hanging wire ropes, for collecting corresponding The oil pressure signal of the balance cylinder.

Further, the first sensing unit includes a plurality of vibration sensors respectively disposed at a lateral position and a longitudinal position of each of the suspension wire ropes on the wire rope tension hydraulic automatic balancing device at the top of the lifting container, for collecting the hanging wire rope Vibration signals in the lateral and longitudinal directions.

Further, further comprising a second sensing unit disposed on or around the lifting reel of the lifting container, electrically connected to the wellhead receiving relay device for real-time acquisition of a rotation capable of characterizing the lifting reel a second state parameter of the number of turns, and transmitting the second state parameter to the wellhead receiving relay device.

Further, the second sensing unit comprises a dual Hall sensor, and two magnetic steels of the dual Hall sensor are symmetrically disposed on two sides of the rotating shaft of the lifting reel for collecting the measured pulse signal.

Further, the first sensing unit includes a plurality of oil pressure sensors and a plurality of vibration sensors, The plurality of oil pressure sensors are respectively disposed on the wire rope tension hydraulic automatic balance device at the top of the lifting container, and corresponding to the bypass of the balance oil cylinders of the respective suspension wire ropes, for collecting the oil pressure signals of the corresponding balance oil cylinders, The vibration sensors are respectively disposed at the lateral and longitudinal positions of the respective suspension wire ropes on the wire rope tension hydraulic automatic balancing device at the top of the lifting container for collecting vibration signals of the suspension wire rope in the lateral direction and the longitudinal direction; the wellhead receiving Data transmission is performed between the device and the resolution gateway by means of frequency hopping communication.

Further, an explosion-proof and intrinsically safe power supply box is further disposed on the top of the lifting container for supplying power to the first sensing unit and the container top relay device; An intrinsically safe collection and delivery box, the wellhead receiving relay device is an intrinsically safe wireless receiving box.

Further, the data display and analysis processing platform includes:

An oil pressure data receiving module, configured to receive the parsed oil pressure data sent by the parsing gateway;

a tension value calculation module, configured to calculate a tension value of the corresponding suspension wire rope according to the oil pressure data;

The first fault prompting module is configured to calculate the tension unbalance degree, the impact load, the lift load or the oil pressure change amount of the suspension wire rope according to the oil pressure data and the tension value, and perform display and fault prompt according to the preset threshold value.

Further, the data display and analysis processing platform includes:

a pulse data receiving module, configured to receive the parsed pulse data sent by the parsing gateway;

a depth calculation module, configured to calculate a depth of the lifting container according to the pulse data;

a depth display module for displaying the depth of the lifting container in real time.

Further, the data display and analysis processing platform includes:

a vibration data receiving module, configured to receive the parsed vibration data sent by the parsing gateway;

a spectrogram obtaining module, configured to calculate a vibration displacement map of the corresponding suspension wire rope according to the vibration data, and obtain a spectrogram by a fast Fourier transform;

The second fault prompting module is configured to determine, according to the preset threshold, whether the vibration displacement exceeds the limit or whether the external excitation frequency is close to the natural frequency of the lifting container, and display and fault prompting.

Further, the container top relay device is further configured to transmit the power parameter of the explosion-proof and intrinsically safe power box to the wellhead receiving relay device;

The data display and analysis processing platform includes:

a power data receiving module, configured to receive the parsed power data sent by the parsing gateway;

The power alarm module is configured to determine whether the battery is insufficient according to a preset threshold, and display and fault prompts.

To achieve the above object, the present invention provides an online monitoring method for the aforementioned on-line monitoring system for lifting a wire rope of a container, comprising:

The first sensing unit collects a first state parameter capable of characterizing the suspended wire rope in real time and transmits it to the container top relay device;

Receiving, by the container top relay device, the first state parameter collected by the sensing unit, and transmitting the first state parameter to the wellhead receiving relay device by frequency hopping spread spectrum and time division multiple access wireless technology;

The wellhead receiving relay device transmits the received data to the data display and analysis processing platform via the parsing gateway for data display, analysis, and processing.

Further, the operation of the wellhead receiving relay device to send the received data to the data display and analysis processing platform via the parsing gateway comprises:

The wellhead receiving relay device transmits the received data to the resolution gateway by means of frequency hopping communication;

After parsing the received data, the parsing gateway sends the data to the data display and analysis processing platform.

Further, the first state parameter includes oil pressure signals corresponding to the balance cylinders of the respective suspension wire ropes respectively disposed on the wire rope tension hydraulic automatic balancing device at the top of the lifting container.

Further, the first state parameter includes vibration signals of the respective suspension wires on the wire rope tension hydraulic automatic balancing device respectively disposed at the top of the lifting container in the lateral direction and the longitudinal direction.

Further, the lifting container suspension wire rope on-line monitoring system further includes a second sensing unit disposed on or around the lifting reel of the lifting container, electrically connected to the wellhead receiving relay device; the online monitoring The method further includes: before the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the resolution gateway,

The second sensing unit collects a second state parameter capable of characterizing the number of revolutions of the hoist drum in real time, and transmits the second state parameter to the wellhead receiving relay device.

Further, the second state parameter includes a pulse signal collected by two pieces of magnetic steel symmetrically disposed on two sides of the rotating shaft of the hoist drum.

Further, after the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the method further includes:

The data display and analysis processing platform receives the parsed oil pressure data sent by the parsing gateway, and calculates a tension value of the corresponding suspension wire rope according to the oil pressure data;

The data display and analysis processing platform calculates the tension unbalance degree, the impact load, the lifting load or the oil pressure change amount of the suspension wire rope according to the oil pressure data and the tension value, and displays and indicates the fault according to the preset threshold value.

Further, after the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the method further includes:

The data display and analysis processing platform receives the parsed pulse data sent by the parsing gateway, and calculates a decentralized depth of the lifting container according to the pulse data;

The data display and analysis processing platform displays the depth of the lifting container in real time.

Further, after the wellhead receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, the method further includes:

The data display and analysis processing platform receives the parsed vibration data sent by the parsing gateway, and calculates a vibration displacement map of the corresponding suspension wire rope according to the vibration data, and then obtains a spectrogram by fast Fourier transform;

The data display and analysis processing platform determines whether the vibration displacement exceeds the limit or whether the external excitation frequency is close to the natural frequency of the lifting container according to a preset threshold, and displays and indicates a fault.

Further, an explosion-proof and intrinsically safe power box is disposed on the top of the lifting container for supplying power to the first sensing unit and the container top relay device; the online monitoring method further includes:

The container top relay device transmits the power parameter of the explosion-proof and intrinsically safe power box to the wellhead receiving relay device;

The data display and analysis processing platform receives the parsed power data sent by the parsing gateway, and determines whether the battery is insufficient according to a preset threshold, and performs display and fault prompting.

Based on the above technical solution, the present invention receives the state parameters of the suspended wire rope collected from the first sensing unit in real time by lifting the container top relay device disposed at the top of the container, so as to realize the real-time operation of the lifting container hanging wire rope during the cycle operation. Intermittent monitoring, and through the frequency hopping spread spectrum and time division multiple access wireless technology to the wellhead receiving relay device for data transmission, because the wireless communication method used for data transmission has better stability, anti-interference and long-distance transmission characteristics, Therefore, the online monitoring system in the deep well environment has better reliability and safety.

DRAWINGS

The drawings described herein are intended to provide a further understanding of the invention, and are intended to be a part of the invention. In the drawing:

1 is a schematic view showing an embodiment of an on-line monitoring system for lifting a wire rope of a container according to the present invention.

2 is a schematic view showing the principle of another embodiment of the on-line monitoring system for lifting the suspension wire of the container according to the present invention.

3 is a schematic view showing the principle of another embodiment of the on-line monitoring system for lifting the suspension wire of the container according to the present invention.

4 is a schematic structural view of an embodiment of an on-line monitoring system for lifting a suspension wire rope of a container according to the present invention.

FIG. 5 is a schematic view showing the arrangement of the vibration sensor in the embodiment of the on-line monitoring system for lifting the wire rope of the container according to the present invention.

Figure 6 is a schematic view showing the arrangement of the oil pressure sensor in the embodiment of the on-line monitoring system for lifting the wire rope of the container according to the present invention.

FIG. 7 is a schematic diagram showing the principle of a frequency hopping communication method in an embodiment of an on-line monitoring system for lifting a wire rope of a container according to the present invention.

FIG. 8 is a schematic flow chart of an embodiment of an online monitoring method according to the present invention.

FIG. 9 is a schematic flow chart of another embodiment of an online monitoring method according to the present invention.

FIG. 10 is a schematic diagram of a process of receiving and processing oil pressure data in an embodiment of an online monitoring method according to the present invention.

FIG. 11 is a schematic diagram of a process of receiving and processing pulse data in an embodiment of an online monitoring method according to the present invention.

FIG. 12 is a schematic diagram of a process of receiving and processing vibration data in an embodiment of an online monitoring method according to the present invention.

Detailed ways

The technical solution of the present invention will be further described in detail below through the accompanying drawings and embodiments.

As shown in FIG. 1 , it is a schematic diagram of an embodiment of an on-line monitoring system for lifting a wire rope of a container according to the present invention. The lifting container hanging wire rope online monitoring system of the present embodiment includes: a first sensing unit 10, a container top relay device 20, a wellhead receiving relay device 30, a resolution gateway 40, and data, in conjunction with the arrangement diagrams shown in FIGS. 4-6. The processing platform 50 is displayed and analyzed.

The first sensing unit 10 is used to acquire a first state parameter capable of characterizing the suspension wire 3 in real time. The first sensing unit 10 may include a plurality of oil pressure sensors 11 respectively disposed on the wire rope tension hydraulic automatic balancing device 2 at the top of the lifting container 1 on the bypass of the balancing oil cylinders corresponding to the respective suspension wire ropes 3, for collecting Corresponding oil pressure signal of the balance cylinder. The collected oil pressure signal can be converted into the corresponding tension value of the suspension wire rope according to the piston bearing pressure area of the balance cylinder in the subsequent processing step, and the tension difference between the plurality of suspension wire ropes is further calculated, so that the lifting system can be not damaged. In the case of structure and stability, accurate and effective monitoring results are obtained.

For example, the A/D conversion reference voltage V _REF set in the on-line monitoring system of the lifting container suspension wire rope is x V, the conversion precision is 12 bits, and the voltage signal of the tension oil pressure sensor output signal is adjusted to V _IN , and the conversion result is For the ADC, then

The oil pressure sensor has a range of 0 to p MPa. The output current signal passes through the precision resistor and the corresponding voltage is y to z V. The monitored oil pressure is P, in MPa.

Substituting V _IN

If the pressure bearing area of the balance cylinder is S cm ² , the calculation formula of the tension F of the suspension wire rope is

The first sensing unit 10 may further include a plurality of vibration sensors 12, which are respectively disposed at lateral and longitudinal positions of the respective suspension wire ropes 3 on the wire rope tension hydraulic automatic balancing device 2 at the top of the lifting container 1, for collecting the suspension The vibration signal of the wire rope 3 in the lateral and longitudinal directions. By monitoring the vibration signals in the lateral and longitudinal directions of the suspension wire 3, the influence of the vibration of the suspension wire 3 on the vibration plane perpendicular to the elongation direction on the amplitude of the lifting system can be more comprehensively investigated, and whether resonance exists can be determined. possibility.

The vibration signal generated by the suspension wire rope during operation is received by a vibration sensor (such as a vibration acceleration sensor, etc.), and the vibration displacement map of the suspension wire rope can be obtained by integrating the budget, and then the spectrum map is obtained by fast Fourier transform. It is assumed that the connection between the lifting container and the wire rope is the origin of the coordinate, and the orientation is positive, and the length l(t) of the hanging wire rope changes with time t, and the linear density is ρ. H is the maximum height of the lifting of the lifting vessel, and the length of the balancing wire rope is Hl(t), which varies with time t, and the linear density is ρ ₂ . Enhance the quality of containers _{m, m e = m + (} Hl (t)) ρ 2 seen from the basic formula and the container lifting rope of the equivalent mass m _e, deep lift during operation due to the balance rope wire rope, an equivalent mass m _e Changes have been made, so that the natural frequency of the lifting container also changes, and the resulting spectrogram can monitor the influence of the external excitation frequency on the system amplitude and the possibility of resonance.

In the embodiment shown in FIG. 4, the first sensing unit 10 can simultaneously include the above-described oil pressure sensor 11 and vibration sensor 12 to realize real-time monitoring of the tension and vibration of the suspension wire rope 3. In other embodiments, the first state parameter characterizing the suspension wire 3 is not limited to the above-described oil pressure and vibration parameters, and may include other parameters, such as tension parameters, and the corresponding first sensing unit 10 may further include a tension sensor or the like. Any sensing unit capable of characterizing the state parameters of the suspended wire rope 3 in real time.

Referring to FIG. 4, the container top relay device 20 is disposed at the top of the lifting container 1 and is electrically connected to the first sensing unit 10 for receiving the first state parameter collected by the first sensing unit 10. Container top The first state parameter is transmitted between the part relay device 20 and the wellhead receiving relay device 30 by wireless communication. For deep well environment 5 such as mines and elevator shafts, many factors such as large well depth and interference in the well facilities will seriously restrict the outward transmission of the sensing signals, which is prone to signal distortion. In this embodiment, The first state parameter can be transmitted to the wellhead receiving relay device 30 by frequency hopping spread spectrum and time division multiple access wireless techniques.

Frequency hopping spread spectrum and time division multiple access wireless technology is a frequency hopping spread spectrum (FHSS) wireless communication technology under a time division multiple access (TDMA) control network architecture. The frequency hopping spread spectrum technology can enable the communication frequency between the gateway and the node to periodically hop between different frequencies according to the hopping table generated by the random sequence code, so as not only can avoid interference from other wireless signals of the same frequency, It does not interfere with other wireless signals, greatly improving the wireless field survivability. In the time division multiple access control network architecture, each node is assigned a communication time slot, thereby ensuring reliable communication between the node and the gateway.

The above-mentioned wireless communication method used for data transmission has better stability, anti-interference and long-distance transmission characteristics (for example, a transmission distance greater than 3.2 km), so that the online monitoring system in a deep well environment has better reliability and safety. In addition, since frequency hopping spread spectrum and time division multiple access wireless technologies are already mature technologies, the specific implementation process will not be described here.

The wellhead receiving relay device 30 is disposed at the inner wall of the wellbore or the wellhead for transmitting the received data to the data display and analysis processing platform 50 via the resolution gateway 40 for data display, analysis, and processing. Wherein, considering that the wellhead receiving relay device 30 may need to send multiple status parameters to the parsing gateway, if the interference during the transmission process will affect the accuracy of the monitoring result, it is preferable to receive the relay device 30 and the parsing at the wellhead. The frequency transfer communication mode is adopted between the gateways 40 for data transmission.

The frequency hopping communication is a communication method in which the carrier frequency of the transmission and reception signals of the two parties is discretely changed according to a predetermined rule, that is, the carrier frequency used in the communication is randomly hopped by the control of the pseudo random variation code. Compared with fixed-frequency communication, the frequency hopping communication method has good anti-interference ability, and even if some frequency points are interfered, normal communication can be performed at other uninterrupted frequency points.

When the frequency hopping communication is applied to the data transmission of the wellhead receiving relay device 30 to the resolution gateway 40 in the embodiment, referring to FIG. 7, the frequency synthesizer on the transmitting side controls the output according to the frequency hopping command issued by the frequency hopping command generator. The frequency of the carrier signal. Correspondingly, as the frequency hopping command generator continuously issues instructions, the control frequency synthesizer constantly changes the frequency of its output carrier so that the mixer outputs the modulated carrier. The frequency will also continually jump with the command, so that the sensing signals are switched to different data transmission channels for transmission according to the frequency hopping sequence. When the receiving side receives the data, the original data is obtained by processing in the same frequency hopping sequence as the transmitting side.

In addition to the status parameters from the suspended wire rope, monitoring of the depth of the lifting vessel can also be achieved in the on-line monitoring system for the lifting vessel suspension wire rope. FIG. 2 is a schematic diagram showing the principle of another embodiment of the on-line monitoring system for lifting the wire rope of the container according to the present invention. The present embodiment further includes a second sensing unit 60 disposed on or around the hoist drum 4 of the lifting container 1 as compared to the previous embodiment. The second sensing unit 60 is electrically connected to the wellhead receiving relay device 30 for real-time collecting a second state parameter capable of characterizing the number of revolutions of the lifting reel, and the second state parameter is The wellhead receiving relay device 30 transmits. The second sensing unit 60 may include a dual Hall sensor. The two magnetic steels of the dual Hall sensor are symmetrically disposed on both sides of the rotating shaft of the lifting reel 4 for collecting the measured pulse signal. When the rotating shaft of the hoisting drum 4 is rotated, the number of revolutions of the reel can be calculated according to the number of pulses measured by the double Hall sensor and the rotating direction of the drum, and the suspension wire rope 3 taken out from the hoisting drum 4 is determined. The length, in turn, determines the specific lower depth position of the lifting vessel 1 in the deep well environment 5.

For example, the two magnets of the double Hall sensor have a pitch of about 8 mm and are provided with marking lines along the direction of rotation of the magnetic steel. When the number of measured pulses is n and the diameter of the lifting reel 4 is d, the lowering depth S of the lifting container 1 can be calculated by the following formula:

As shown in FIG. 3, it is a schematic diagram of another embodiment of the on-line monitoring system for lifting the wire rope of the container of the present invention. Compared with the previous system embodiments, the present embodiment is further provided with a power box 70 on the top of the lifting container 1 for supplying power to the first sensing unit 10 and the container top relay device 20. For a mine environment at risk of explosion, the power box 70 preferably employs an explosion-proof and intrinsically safe power box having a flameproof enclosure and some of the circuits are intrinsically safe. The container top relay device 20 preferably employs an intrinsically safe type of acquisition and transmission box in which all circuits are intrinsically safe, and the wellhead receiving relay device 30 preferably employs an intrinsically safe wireless receiving box in which all circuits are intrinsically safe.

In each of the above system embodiments, the data display and analysis processing platform 50 can be implemented by one or more servers, general purpose computers, or industrial control computers. In the data display and analysis processing platform 50 Multiple monitoring and analysis software can be run inside to implement the corresponding data processing functions.

For the embodiment in which the first sensing unit 10 includes a plurality of oil pressure sensors 11, the oil pressure signal of the balance cylinder collected by the oil pressure sensor 11 passes through the container top relay device 20, the wellhead receiving relay device 30, and the analysis. Gateway 40 arrives at data display and analysis processing platform 50. Correspondingly, the data display and analysis processing platform 50 may specifically include: an oil pressure data receiving module, a tension value calculating module, and a first fault prompting module. The oil pressure data receiving module is configured to receive the analyzed hydraulic pressure data sent by the analysis gateway 40, and the hydraulic pressure data corresponds to the oil pressure signal collected by the oil pressure sensor 11. The tension value calculation module is configured to calculate a tension value of the corresponding suspension wire rope 3 according to the oil pressure data, and the specific calculation process may refer to the foregoing examples and calculation formulas. The first fault prompting module is configured to calculate the tension unbalance degree, the impact load, the lifting load or the oil pressure change amount of the suspension wire rope 3 according to the oil pressure data and the tension value, and perform display and fault prompt according to the preset threshold value.

For example, the first fault prompting module can implement the following functions:

A, tension imbalance alarm and imbalance indication

For example, when a lifting container (such as a bucket/cage, etc.) is lifted with four hanging wire ropes, the tension unbalance B of the hanging wire rope can be calculated by the following formula:

Wherein, F _i is the tension value of the i-th suspension wire rope, i=1 to 4.

When the tension imbalance exceeds a preset threshold (for example, 10%), the indicator light corresponding to the tension imbalance condition will become red indicating the warning, and an audible alarm (for example, three consecutive alarm sounds). In addition, the tension imbalance of the current suspension wire rope can be displayed in real time through the indicator bar of the tension unbalance degree.

B, impact load

When the bucket is stopped or stuck in the hoistway and cannot be lifted, the suspension wire rope will be subjected to a huge impact load. At this time, the tension value of the suspension wire rope exceeds the preset safety threshold, and the indicator light corresponding to the impact load will become red indicating the warning. An audible alarm (such as a continuous voice alarm tone) can be issued.

C, overload alarm

For applications that require the use of lifting containers to hold materials, such as in a coal mine environment, the load is calculated based on the weight of the load and the weight of the empty bucket. When the bucket load exceeds the overload alarm setting or the lift load is greater than the preload When the lifting load threshold is set, the indicator corresponding to the overload alarm will change to red indicating the warning, and an audible alarm (such as three consecutive voice alarms) can be issued to remind the staff not to start the lifting system under overload conditions.

D, card cylinder alarm

If the balance cylinder is stuck, the internal oil pressure will be stable. Therefore, according to whether the oil pressure change amount within the preset time range is less than the preset threshold value, it is determined whether the card cylinder condition has occurred. When the card cylinder is determined, the corresponding The indicator light on the card cylinder will change to red indicating the warning and an audible alarm (such as a continuous alarm tone).

In addition, the data display and analysis processing platform 50 is also capable of drawing a wire rope tension curve based on the tension value of the suspended wire rope and displaying the curve. The ordinate of the curve can be selected as the tension value, and the abscissa can be selected as the depth value of the lifting container, or the time can be selected.

For the embodiment in which the first sensing unit 10 includes a plurality of vibration sensors 12, the vibration signals collected by the vibration sensor 12 in the lateral and longitudinal directions pass through the container top relay device 20, the wellhead receiving relay device 30, and the resolution gateway. 40 arrives at the data display and analysis processing platform 50. Correspondingly, the data display and analysis processing platform 50 may specifically include: a vibration data receiving module, a spectrogram obtaining module, and a second fault prompting module. The vibration data receiving module is configured to receive the parsed vibration data sent by the analysis gateway 40. The spectrogram obtaining module is configured to calculate a vibration displacement map of the corresponding suspension wire rope 3 according to the vibration data, and then obtain a spectrogram by fast Fourier transform. The second fault prompting module is configured to determine, according to the preset threshold, whether the vibration displacement is out of limits or whether the external excitation frequency is close to the natural frequency of the lifting container 1, and display and fault prompting.

For example, the second fault prompting module can implement the following functions:

E. Comparing the calculated vibration displacement with a preset threshold to determine whether the vibration displacement is over-limit. If the vibration displacement is exceeded, the indicator light corresponding to the vibration displacement over-limit will become red indicating the warning, and An audible alarm (such as a continuous alarm tone).

F. Comparing the natural frequency of the lifting container determined by the fast Fourier transform with the external excitation frequency, if the natural frequency of the lifting container is very close to the external excitation frequency, resonance may occur. The indicator light corresponding to the resonance will change to red indicating the warning and an audible alarm (such as a continuous alarm tone).

For the above embodiment including the second sensing unit 60 (for example, a dual Hall sensor, etc.), the pulse signal collected by the second sensing unit 60 passes through the container top relay device 20, the wellhead receiving relay device 30, and the analysis. Gateway 40 arrives at data display and analysis processing platform 50. Correspondingly, the data display and analysis processing platform 50 may specifically include: a pulse data receiving module, a drop depth calculating module, and a depth display module. The pulse data receiving module is configured to receive the parsed pulse data sent by the parsing gateway 40. The lowering depth calculation module is configured to calculate a depth of the lifting of the lifting container 1 based on the pulse data. The depth display module is used to display the depth of the lifting of the lifting container 1 in real time.

In addition, the data display and analysis processing platform 50 can also display loading and unloading and lifting simulation animations, such as simulating bucket loading, unloading and lifting processes, and displaying the amount of coal in the bucket and unloading the coal in real time in the bucket. The relative position of the bucket in the interface will vary as the actual position of the bucket changes in the well, and the bucket in-position signal can also be indicated.

For a system embodiment including an explosion-proof and intrinsically safe power box, the data display and analysis processing platform 50 can include a power data receiving module and a power alarm module. The power data receiving module is configured to receive the parsed power data sent by the parsing gateway 40. The power alarm module is configured to determine whether the battery is insufficient according to a preset threshold, and display and fault prompts.

In each of the above system embodiments, the data display and analysis processing platform 50 can also store alarm records and provide an inquiry function for alarm records.

The present invention also provides an online monitoring method based on the above embodiments of the hoisting wire rope on-line monitoring system. As shown in FIG. 8 , it is a schematic flowchart of an embodiment of the online monitoring method of the present invention. In this embodiment, the online monitoring method includes:

Step 100, the first sensing unit 10 collects the first state parameter capable of characterizing the suspension wire rope 3 and transmits it to the container top relay device 20;

Step 200: The container top relay device 20 receives the first state parameter collected by the sensing unit, and receives the first state parameter into the wellhead by using frequency hopping spread spectrum and time division multiple access wireless technology. Following device 30 transmission;

Step 300, the wellhead receiving relay device 30 transmits the received data to the parsing gateway 40. It is sent to the data display and analysis processing platform 50 for display, analysis and processing of data.

In this embodiment, the first state parameter may include oil pressure signals corresponding to the balance cylinders of the respective suspension wire ropes 3 respectively disposed on the wire rope tension hydraulic automatic balancing device 2 at the top of the lifting container 1, and may also include respectively setting Vibration signals in the lateral and longitudinal directions of the respective suspension wire ropes 3 on the wire rope tension hydraulic automatic balancing device 2 at the top of the lifting vessel 1.

Fig. 9 shows another embodiment of the online monitoring method of the present invention. Compared with the previous embodiment, the step 300 of this embodiment specifically includes:

Step 310, the wellhead receiving relay device 30 transmits the received data to the resolution gateway 40 by means of frequency hopping communication;

Step 320: The parsing gateway 40 parses the received data and sends the received data to the data display and analysis processing platform 50.

In addition, for the foregoing embodiment of the hoisting wire suspension wire rope monitoring system including the second sensing unit 60, before step 300, the method further includes:

Step 600: The second sensing unit 60 collects a second state parameter capable of characterizing the number of revolutions of the lifting reel in real time, and transmits the second state parameter to the wellhead receiving relay device 30. The second state parameter may include a pulse signal measured by two pieces of magnetic steel symmetrically disposed on both sides of the rotating shaft of the hoist drum.

For different sensory data, the data display and analysis processing platform 50 is capable of implementing corresponding receiving and processing processes. FIG. 10 is a schematic diagram showing the process of receiving and processing oil pressure data in the embodiment of the online monitoring method of the present invention. For the oil pressure signal of the balance cylinder, the receiving and processing of the data display and analysis processing platform 50 includes:

Step 411, the data display and analysis processing platform 50 receives the parsed oil pressure data sent by the parsing gateway 40;

Step 412, the data display and analysis processing platform 50 calculates the tension value of the corresponding suspension wire rope 3 according to the oil pressure data;

Step 413, the data display and analysis processing platform 50 calculates the tension unbalance degree of the suspension wire rope 3 according to the tension value, and determines whether the tension imbalance degree is less than a preset threshold value, and indicates that the red light of the warning light is on, otherwise the normal green light is on. ;

Step 414, the data display and analysis processing platform 50 determines whether the lifting load of the suspension wire rope 3 is subjected to an impact load according to the tension value, and indicates that the red light of the impact load alarm is bright, otherwise the normal green light is bright;

Step 415: The data display and analysis processing platform 50 determines whether the lifting load is greater than a preset threshold according to the tension value, and indicates that the red light of the overload alarm is on, otherwise the normal green light is on;

Step 416: The data display and analysis processing platform 50 calculates the oil pressure change amount according to the oil pressure data, and determines whether the oil pressure change amount is less than a preset threshold value, and indicates that the red light of the card cylinder alarm is on, otherwise the normal green light is on.

FIG. 11 is a schematic diagram of a process of receiving and processing pulse data in an embodiment of an online monitoring method according to the present invention. For the pulse signals collected by the dual Hall sensors, the receiving and processing of the data display and analysis processing platform 50 includes:

Step 421: The data display and analysis processing platform 50 receives the parsed pulse data sent by the parsing gateway 40.

Step 422, the data display and analysis processing platform 50 calculates the drop depth of the lifting container 1 according to the pulse data;

Step 423, the data display and analysis processing platform 50 displays the depth of the lifting of the lifting container 1 in real time.

FIG. 12 is a schematic diagram showing the process of receiving and processing vibration data in the embodiment of the online monitoring method of the present invention. For the lateral and longitudinal vibration signals of the wire rope, the receiving and processing of the data display and analysis processing platform 50 includes:

Step 431, the data display and analysis processing platform 50 receives the parsed vibration data sent by the parsing gateway 40;

Step 432: Calculate a vibration displacement map of the corresponding suspension wire rope 3 according to the vibration data;

Step 433: Perform a fast Fourier transform on the vibration displacement map to obtain a spectrogram;

Step 434, the data display and analysis processing platform 50 determines whether the vibration displacement exceeds the limit or whether the external excitation frequency is close to the natural frequency of the lifting container 1 according to the preset threshold, and the red light indicating the vibration alarm is bright, otherwise it indicates normal. The green light is on.

In addition, for system embodiments including flameproof and intrinsically safe power boxes, online monitoring The method may further include: the container top relay device 20 transmits the power parameter of the explosion-proof and intrinsically safe power box to the wellhead receiving relay device 30; the data display and analysis processing platform 50 receives the resolution gateway 40 The parsed power data is sent, and it is judged according to the preset threshold whether the battery is insufficient, and the display and the fault prompt are performed.

It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to be limiting; although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that The invention is not limited to the spirit of the technical solutions of the present invention, and should be included in the scope of the technical solutions claimed in the present invention.

Claims (22)

An online monitoring system for lifting a suspension wire rope of a container, comprising: a first sensing unit, a container top relay device, a wellhead receiving relay device, a resolution gateway, and a data display and analysis processing platform; the first sensing unit is used for real-time Collecting a first state parameter capable of characterizing the suspension wire rope; the container top relay device is disposed at the top of the lifting container and electrically connected to the first sensing unit for receiving the first sensing unit to collect a first state parameter, and transmitting the first state parameter to the wellhead receiving relay device by frequency hopping spread spectrum and time division multiple access wireless technology; the wellhead receiving relay device is disposed at an inner wall of the wellbore or a wellhead, The received data is sent to the data display and analysis processing platform via the parsing gateway for display, analysis, and processing of the data. The hoisting wire rope on-line monitoring system of claim 1 , wherein the wellhead receiving relay device and the analytic gateway perform data transmission by means of frequency hopping communication. The hoisting wire rope on-line monitoring system of claim 1 , wherein the first sensing unit comprises a plurality of oil pressure sensors, respectively disposed on a wire rope tension hydraulic automatic balancing device at the top of the lifting container, corresponding to each piece The bypass of the balance cylinder of the suspension wire rope is used to collect the oil pressure signal of the corresponding balance cylinder. The lifting container hanging wire rope online monitoring system according to claim 1, wherein the first sensing unit comprises a plurality of vibration sensors, and each of the suspension wire ropes respectively disposed on the wire rope tension hydraulic automatic balancing device at the top of the lifting container The lateral and longitudinal positions are used to acquire vibration signals of the suspended wire rope in the lateral and longitudinal directions. The on-line monitoring system for a lifting container suspension wire rope according to claim 1, further comprising a second sensing unit disposed on or around the lifting reel of the lifting container, electrically connected to the wellhead receiving relay device, And a second state parameter capable of characterizing the number of revolutions of the hoist drum in real time, and transmitting the second state parameter to the wellhead receiving relay device. The lifting container suspension wire rope on-line monitoring system according to claim 5, wherein said second sensing unit comprises a double Hall sensor, and two magnetic steels of said double Hall sensor are symmetrically disposed on said lifting drum Both sides of the shaft are used to acquire the measured pulse signal. A lifting container wire rope online monitoring system according to claim 5, wherein said A sensing unit includes a plurality of oil pressure sensors and a plurality of vibration sensors respectively disposed on the wire rope tension hydraulic automatic balancing device at the top of the lifting container, corresponding to the balance cylinders of the respective suspension wire ropes On the road, for collecting oil pressure signals of the corresponding balance cylinders, the plurality of vibration sensors are respectively disposed at the lateral and longitudinal positions of the respective suspension wire ropes on the wire rope tension hydraulic automatic balance device at the top of the lifting container, for collecting The vibration signal of the suspension wire rope in the lateral direction and the longitudinal direction; the wellhead receiving relay device and the analysis gateway perform data transmission by means of frequency hopping communication. The on-line monitoring system for a lifting container suspension wire rope according to claim 1, wherein an explosion-proof and intrinsically safe power supply box is further disposed on the top of the lifting container for the first sensing unit and the top of the container The device is supplied with power; the container top relay device is an intrinsically safe collection and transmission box, and the wellhead receiving relay device is an intrinsically safe wireless receiving box. The on-line monitoring system for a lifting container suspension wire rope according to claim 3, wherein said data display and analysis processing platform comprises: An oil pressure data receiving module, configured to receive the parsed oil pressure data sent by the parsing gateway; a tension value calculation module, configured to calculate a tension value of the corresponding suspension wire rope according to the oil pressure data; The first fault prompting module is configured to calculate the tension unbalance degree, the impact load, the lift load or the oil pressure change amount of the suspension wire rope according to the oil pressure data and the tension value, and perform display and fault prompt according to the preset threshold value. The on-line monitoring system for lifting wire ropes of a lifting container according to claim 6, wherein the data display and analysis processing platform comprises: a pulse data receiving module, configured to receive the parsed pulse data sent by the parsing gateway; a depth calculation module, configured to calculate a depth of the lifting container according to the pulse data; a depth display module for displaying the depth of the lifting container in real time. The hoisting wire rope on-line monitoring system of claim 4, wherein the data display and analysis processing platform comprises: a vibration data receiving module, configured to receive the parsed vibration data sent by the parsing gateway; a spectrogram obtaining module, configured to calculate a vibration displacement map of the corresponding suspension wire rope according to the vibration data, and obtain a spectrogram by a fast Fourier transform; The second fault prompting module is configured to determine, according to the preset threshold, whether the vibration displacement exceeds the limit or whether the external excitation frequency is close to the natural frequency of the lifting container, and display and fault prompting. The hoisting wire rope on-line monitoring system of claim 8 , wherein the container top relay device is further configured to transmit a power parameter of the explosion-proof and intrinsically safe power box to the wellhead receiving relay device; The data display and analysis processing platform includes: a power data receiving module, configured to receive the parsed power data sent by the parsing gateway; The power alarm module is configured to determine whether the battery is insufficient according to a preset threshold, and display and fault prompts. An on-line monitoring method for an on-line monitoring system for a lifting container suspension wire rope according to any one of claims 1 to 12, comprising: The first sensing unit collects a first state parameter capable of characterizing the suspended wire rope in real time and transmits it to the container top relay device; Receiving, by the container top relay device, the first state parameter collected by the sensing unit, and transmitting the first state parameter to the wellhead receiving relay device by frequency hopping spread spectrum and time division multiple access wireless technology; The wellhead receiving relay device transmits the received data to the data display and analysis processing platform via the parsing gateway for data display, analysis, and processing. The online monitoring method according to claim 13, wherein the operation of the wellhead receiving relay device to send the received data to the data display and analysis processing platform via the resolution gateway comprises: The wellhead receiving relay device transmits the received data to the resolution gateway by means of frequency hopping communication; After parsing the received data, the parsing gateway sends the data to the data display and analysis processing platform. The online monitoring method according to claim 13, wherein said first state parameter comprises oil pressure signals of balance oil cylinders corresponding to respective suspension wire ropes respectively disposed on a wire rope tension hydraulic automatic balancing device at the top of said lifting container. The on-line monitoring method according to claim 13, wherein said first state parameter comprises vibration signals in lateral and longitudinal directions of respective suspension wire ropes respectively disposed on the wire rope tension hydraulic automatic balancing device at the top of said lifting container. The on-line monitoring method according to claim 13, wherein said lifting container suspension wire rope on-line monitoring system further comprises a second sensing unit disposed on or around the lifting drum of said lifting container, and said wellhead receiving And following the device electrical connection; the online monitoring method, before the well receiving relay device sends the received data to the data display and analysis processing platform via the parsing gateway, further comprising: The second sensing unit collects a second state parameter capable of characterizing the number of revolutions of the hoist drum in real time, and transmits the second state parameter to the wellhead receiving relay device. The on-line monitoring method according to claim 17, wherein said second state parameter comprises a measured pulse signal collected by two pieces of magnetic steel of a dual Hall sensor symmetrically disposed on both sides of a rotating shaft of said hoist drum. The online monitoring method according to claim 15, wherein after the wellhead receiving relay device transmits the received data to the data display and analysis processing platform via the resolution gateway, the method further includes: The data display and analysis processing platform receives the parsed oil pressure data sent by the parsing gateway, and calculates a tension value of the corresponding suspension wire rope according to the oil pressure data; The data display and analysis processing platform calculates the tension unbalance degree, the impact load, the lifting load or the oil pressure change amount of the suspension wire rope according to the oil pressure data and the tension value, and displays and indicates the fault according to the preset threshold value. The online monitoring method according to claim 18, wherein after the wellhead receiving relay device transmits the received data to the data display and analysis processing platform via the resolution gateway, the method further includes: The data display and analysis processing platform receives the parsed pulse data sent by the parsing gateway, and calculates a decentralized depth of the lifting container according to the pulse data; The data display and analysis processing platform displays the depth of the lifting container in real time. The online monitoring method according to claim 16, wherein the relay device is received at the wellhead After the received data is sent to the data display and analysis processing platform via the parsing gateway, the method further includes: The data display and analysis processing platform receives the parsed vibration data sent by the parsing gateway, and calculates a vibration displacement map of the corresponding suspension wire rope according to the vibration data, and then obtains a spectrogram by fast Fourier transform; The data display and analysis processing platform determines whether the vibration displacement exceeds the limit or whether the external excitation frequency is close to the natural frequency of the lifting container according to a preset threshold, and displays and indicates a fault. The online monitoring method according to claim 13, wherein an explosion-proof and intrinsically safe power supply box is further provided at the top of the lifting vessel for supplying power to the first sensing unit and the container top relay device The online monitoring method further includes: The container top relay device transmits the power parameter of the explosion-proof and intrinsically safe power box to the wellhead receiving relay device; The data display and analysis processing platform receives the parsed power data sent by the parsing gateway, and determines whether the battery is insufficient according to a preset threshold, and performs display and fault prompting.

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