大型塔式起重机非接触式力矩保护技术研究
摘要
塔式起重机是工业和民用建筑施工中完成重物吊装工作的主要设备，具有工作效率高，使用范围广，操作容易，安装拆卸简便等优点。近年来，核电站及建筑业的迅速发展，为塔式起重机的发展创造了前所未有的发展机会，但同时也提出了挑战，塔式起重机安全事故随着起重机数量的猛增而频繁发生。减少塔式起重机事故，提高塔式起重机安全性能和作业效率迫在眉睫。
力矩限制器是装备在塔式起重机上的重要超载保护装置，它为塔式起重机的安全工作提供保障。传统的力矩保护装置是采用一个机械式的力矩传感器，利用机械变形产生电信号，再将这一信号放大，为操作者提供显示或保护信号；但这种接触式的力矩保护存在着不可避免的误差，为了提高其可靠性和精度，减小误差，本文在对国内外现有的力矩限制器进行了深入详尽的对比和分析基础上，借鉴和传承了它们的成功经验，充分利用现代电子、计算机、传感测控等方面的技术成果，提出了非接触式的设计思想，进行了新型起重机力矩限制器的研制。该系统的解决方案具有通用性好、高精度、低成本等优点。
本文的力矩保护装置是采用非接触的设计思想，从重量和幅度两个方面进行信号检测研究，从而检测出塔式起重机力矩是否达到极限，起到力矩保护的作用。
在重量检测方面，因为塔式起重机一切工作来源于电能，一切情况都直接反映到电动机的输入功率上，因而本文把重量信号检测转变成测电动机功率信号，并通过功率变送器转换成标准电压信号，再传递到计算机的输入接口，利用计算机进行检测重量是否超标；在幅度检测方面，采用旋转变压器来在线检测起重臂的角度变化，并将信号传递到计算机，进行检测幅度是否达到极限。本文中采集的模拟信号是通过转换器转换成数字信号，并利用PLC进行信号处理。从实验结果可以看出，本文采用的设计思想同传统的接触式思想相比较减少了测量误差，提高了精度，从而提高了系统的稳定性。
Tower cranes are major hoisting apparatus of the industrial or civil construction with traits of high working efficiency, wide range of uses, easy manipulation and convenient installation or dismantlement. With the development of the nuclear power station and the architecture industry in recent years, tower cranes are offered the best opportunities for developing which they have never met. But when the number of tower cranes increases rapidly, the number of the tower cranes accidents also increases in large quantity. Therefore it is urgent that the safety of tower cranes should be improved and the rate of tower crane accidents should be reduced.
Crane torque limiter that is equipped on the crane is important overload protective device. It provides safeguard for the safety work of crane. Traditional torque protective device adopts a mechanical torque sensor, through making use of the machinery deformation to produce electric signal, then enlarge it in order to provide the operator with the protective signal. But this kind of no-connection torque protection has the inevitable error. To improve its reliability and accuracy, this paper is based on the deep comparison and analysis of the present domestic and foreign torque limiters, at the same time, make good use of its efficient experience which takes advantage of the technical achievements in the fields such as electronic, computer, sensing and controlling. At last, they brought forward the design idea of the no-connection type and carried out the research of the new-model tower crane torque limiter. The solving scheme in this system has the traits of general availability, high-accuracy and low cost and the like.
The torque protective device in this paper adopts the design idea of the no-connection type, from weight and extent two sides to carry on the study of the signal detection, then examine whether the tower crane is reaching the limit or not. This can play the very important role in protecting the torque.
As for the first aspect, that is, the weight examination, as all the work of the tower crane is from the electric energy, all the situations will be seen directly from the input power of the motor. Therefore in this paper we make use of the method of measuring the electric motor power signal instead of measuring the weight signal, and transfer it into the standard voltage signal by power transmitter, then transfer it to the interface of the computer. At last, check if the weight goes beyond the standard by use of the computer. On the other hand, for the amplitude detection, we adopt the revolution transformer to check the angle change of the jib loading boom on-line and transfer a signal to the computer to check if it extents over the limit. In this paper the collecting signal, that is, the simulated signal will be changed into the digital signal through the converter and then carry out processing the signal by use of the PLC. From the results of the experiment, we can see that having comparing with the traditional design idea, our design idea has the following advantages, such as, reducing the error measurement, improving the accuracy, which results in improving the stability of the whole system.
力矩限制器是装备在塔式起重机上的重要超载保护装置，它为塔式起重机的安全工作提供保障。传统的力矩保护装置是采用一个机械式的力矩传感器，利用机械变形产生电信号，再将这一信号放大，为操作者提供显示或保护信号；但这种接触式的力矩保护存在着不可避免的误差，为了提高其可靠性和精度，减小误差，本文在对国内外现有的力矩限制器进行了深入详尽的对比和分析基础上，借鉴和传承了它们的成功经验，充分利用现代电子、计算机、传感测控等方面的技术成果，提出了非接触式的设计思想，进行了新型起重机力矩限制器的研制。该系统的解决方案具有通用性好、高精度、低成本等优点。
本文的力矩保护装置是采用非接触的设计思想，从重量和幅度两个方面进行信号检测研究，从而检测出塔式起重机力矩是否达到极限，起到力矩保护的作用。
在重量检测方面，因为塔式起重机一切工作来源于电能，一切情况都直接反映到电动机的输入功率上，因而本文把重量信号检测转变成测电动机功率信号，并通过功率变送器转换成标准电压信号，再传递到计算机的输入接口，利用计算机进行检测重量是否超标；在幅度检测方面，采用旋转变压器来在线检测起重臂的角度变化，并将信号传递到计算机，进行检测幅度是否达到极限。本文中采集的模拟信号是通过转换器转换成数字信号，并利用PLC进行信号处理。从实验结果可以看出，本文采用的设计思想同传统的接触式思想相比较减少了测量误差，提高了精度，从而提高了系统的稳定性。
Tower cranes are major hoisting apparatus of the industrial or civil construction with traits of high working efficiency, wide range of uses, easy manipulation and convenient installation or dismantlement. With the development of the nuclear power station and the architecture industry in recent years, tower cranes are offered the best opportunities for developing which they have never met. But when the number of tower cranes increases rapidly, the number of the tower cranes accidents also increases in large quantity. Therefore it is urgent that the safety of tower cranes should be improved and the rate of tower crane accidents should be reduced.
Crane torque limiter that is equipped on the crane is important overload protective device. It provides safeguard for the safety work of crane. Traditional torque protective device adopts a mechanical torque sensor, through making use of the machinery deformation to produce electric signal, then enlarge it in order to provide the operator with the protective signal. But this kind of no-connection torque protection has the inevitable error. To improve its reliability and accuracy, this paper is based on the deep comparison and analysis of the present domestic and foreign torque limiters, at the same time, make good use of its efficient experience which takes advantage of the technical achievements in the fields such as electronic, computer, sensing and controlling. At last, they brought forward the design idea of the no-connection type and carried out the research of the new-model tower crane torque limiter. The solving scheme in this system has the traits of general availability, high-accuracy and low cost and the like.
The torque protective device in this paper adopts the design idea of the no-connection type, from weight and extent two sides to carry on the study of the signal detection, then examine whether the tower crane is reaching the limit or not. This can play the very important role in protecting the torque.
As for the first aspect, that is, the weight examination, as all the work of the tower crane is from the electric energy, all the situations will be seen directly from the input power of the motor. Therefore in this paper we make use of the method of measuring the electric motor power signal instead of measuring the weight signal, and transfer it into the standard voltage signal by power transmitter, then transfer it to the interface of the computer. At last, check if the weight goes beyond the standard by use of the computer. On the other hand, for the amplitude detection, we adopt the revolution transformer to check the angle change of the jib loading boom on-line and transfer a signal to the computer to check if it extents over the limit. In this paper the collecting signal, that is, the simulated signal will be changed into the digital signal through the converter and then carry out processing the signal by use of the PLC. From the results of the experiment, we can see that having comparing with the traditional design idea, our design idea has the following advantages, such as, reducing the error measurement, improving the accuracy, which results in improving the stability of the whole system.
引文
[1]卓先领．2003年1～4月份我国工程起重机市场回眸．工程机械与维修，2003，7：70-71
[2]荀志远．起重机械事故原因分析及对策．起重运输机械，2003，8：55—57
[3]Cliff schexnayder, P.E Crane Accidents. Practice Periodical on Structural Desihn and Construction, 2003, MAY: 67-73
[4]甄正义，唐超．起重机多功能安全保护装置．起重运输机械，1996，1：11-15
[5]王积永，宋世军．塔式起重力矩限制器．起重运输机械，2000(11)：21-22
[6]邵宪琴．塔式起重机的安全装置设计．建筑机械，1998(10)：14—18
[7]龙刚强．国外工程机械控制技术现状与发展趋势．工程机械与维修，2003，7：70-71
[8]王积水等．塔式起重机安全装置现状浅析．工程机械，2002(2)：20-22
[9]颜大平．塔式起重机安全状况的评估．建筑机械，1994(8)：48-49
[10]高继勇．MCS-51单片机汽车起重机安全报警保护装置的研制．河北工学院学报，1995，1：1-4
[11]张元良，鞠欣．基于W77E58的起重机力矩限制器．起重运输机械，2004(8)：30-31
[12]吴丽萍．塔式起重机安全装置的性能分析．山西机械，2003，2：39—40
[13]胡春生等．塔机弹性钢板式力矩限制器的应用．建筑机械，1988(12)：32—34
[14]成红梅．塔式起重机安全装置试验方法的研究．山东建筑工程学院学报，2003(2)：51-53
[15]刘佩衡．国内外塔式起重机发展概况．工程机械与维修，1997(8)：12—13
[16]张元良，刘欣，屈福政等．80C552在起重机力矩限制器中的应用．工程机械，1998，5：41-43
[17]刘佩衡．国外建筑用塔吊发展近况．建筑技术，1995(8)：509—512
[18]Brown G, michon G, and Peyriere J. On the multifractal analysis lf measures [J]. Joural If Star plrys, 1992, 6(6): 775-790.
[19]Berroir JP. Analyse multifractale dimages [J]. Universite depairs Ⅸ, 1993, 12(12):552-556.
[20]Levy vehel J, Daoudl, Generalized IFS for signal processing[J], IEEE DSP Workshop, 1996, 9(2): 1-4
[21]Canus c, Robust large deviation multifractal spection estimation[C]. Tangier:Proceedings of International Wavelets Conference, 1998: 739-742.
[22]Levy Vehel J. Numerical computation of the large deviation muitifractal spectrum[C]. Rome: CFIC, 1996: 102-105.
[23]Levy Vehel J. Introduction to the multifractal analysis of imanes fractal image encoding and analysis [M].Springer Verfag: Y Fisher Editor, 1996:30-32
[24]Zhang M iugqin: The Safety Device and D iagnostic System for Tower Crane, Proceedings of Jmternational Comference on Advanced Technology and Equipment of Materials Handling, Beijing: China Machine Press, 1994:22-23
[25]刘佩衡．建筑塔吊市场预测及塔吊产品技术开发展望．建筑技术开发，1999(6)：42—50
[26]吴丽萍．我国起重机的新技术进展与国外发展动向．山西机械，2002(12)：51-55
[27]赵向阳，张宏，胡景清．工程机械控制系统的新发展．徐州工程机械，2003，2：59
[28]范俊祥．塔式起重机．中国建材工业出版社，2004，7：1-9，132-136
[29]孙在鲁．塔式起重机应用技术．中国建材工业出版社，2003，6：76-79
[30]CLAIMS JOHN SMTTB. Quslity is key to safety. CRANES TODAY, 1988(3):27 (2)
[31]Al-lami,B.J. (Inelec Inst);Benazzouz,,D. Microprocessor based crane load state monitoring system. IEE Conference Publication, v2, n332,1991,1183-1186
[32]Bernold, Leonhard E. (North Carolina State Univ):Lorenc, Steven J.:Luces, Erick. On-line assistance for crane operators. Journal of Computing in Civil Engineering, v11, n4,Oct, 1997, 248-259
[33]韦博军．塔式起重机力矩限制器技术状况的调查．建筑安全，1997(2)：9-10
[34]段为．塔式起重机力矩限制器的调试．建筑机械，1997(5)：28-30
[35]付剑雄．力矩限制器调整及系统综合精度计算．建筑机械，1996(9)12—20
[36]张炳义，王凤翔，冯桂宏．非接触式起重机力矩保护装置的改进．起重运输机械，1999(8)：26—28
[37]张炳义．新型非接触式起重机力矩保护装置．起重运输机械，1999(5)：28-30
[38]武建文，李德成．电机现代测试技术．机械工业出版社，2005：101—102
[39]张福学．传感器应用及其电路精选．北京：电子工业出版社，1993：90-92
[40]杨渝钦．控制电机．机械工业出版社，2001：109-117
[41]杨书华，霍孟友．微机原理及硬件接口技术．机械工业出版社，2004，1：228-286
[42]赵保经，罗振候，范敏等．A／D和D／A转换器应用手册．上海：上海科学普及出版社，1995：62—69
[43]王益全，张炳义．电机测试技术．科学出版社，2004：198-203
[44]王显正，陈正航．控制理论基础．北京国防工来出版社，1989．52—65
[45]王幸之等．单片机应用系统抗干扰技术．北京航空航天大学出版社，1999，12：347-375
[46]王庆斌，刘萍，尤利文．电磁干扰与电磁兼容技术．北京：机械工业出版社，1999：136-171
[47]陈伯时．电力拖动自动控制系统．机械工业出版社，2000，6：189—261
[2]荀志远．起重机械事故原因分析及对策．起重运输机械，2003，8：55—57
[3]Cliff schexnayder, P.E Crane Accidents. Practice Periodical on Structural Desihn and Construction, 2003, MAY: 67-73
[4]甄正义，唐超．起重机多功能安全保护装置．起重运输机械，1996，1：11-15
[5]王积永，宋世军．塔式起重力矩限制器．起重运输机械，2000(11)：21-22
[6]邵宪琴．塔式起重机的安全装置设计．建筑机械，1998(10)：14—18
[7]龙刚强．国外工程机械控制技术现状与发展趋势．工程机械与维修，2003，7：70-71
[8]王积水等．塔式起重机安全装置现状浅析．工程机械，2002(2)：20-22
[9]颜大平．塔式起重机安全状况的评估．建筑机械，1994(8)：48-49
[10]高继勇．MCS-51单片机汽车起重机安全报警保护装置的研制．河北工学院学报，1995，1：1-4
[11]张元良，鞠欣．基于W77E58的起重机力矩限制器．起重运输机械，2004(8)：30-31
[12]吴丽萍．塔式起重机安全装置的性能分析．山西机械，2003，2：39—40
[13]胡春生等．塔机弹性钢板式力矩限制器的应用．建筑机械，1988(12)：32—34
[14]成红梅．塔式起重机安全装置试验方法的研究．山东建筑工程学院学报，2003(2)：51-53
[15]刘佩衡．国内外塔式起重机发展概况．工程机械与维修，1997(8)：12—13
[16]张元良，刘欣，屈福政等．80C552在起重机力矩限制器中的应用．工程机械，1998，5：41-43
[17]刘佩衡．国外建筑用塔吊发展近况．建筑技术，1995(8)：509—512
[18]Brown G, michon G, and Peyriere J. On the multifractal analysis lf measures [J]. Joural If Star plrys, 1992, 6(6): 775-790.
[19]Berroir JP. Analyse multifractale dimages [J]. Universite depairs Ⅸ, 1993, 12(12):552-556.
[20]Levy vehel J, Daoudl, Generalized IFS for signal processing[J], IEEE DSP Workshop, 1996, 9(2): 1-4
[21]Canus c, Robust large deviation multifractal spection estimation[C]. Tangier:Proceedings of International Wavelets Conference, 1998: 739-742.
[22]Levy Vehel J. Numerical computation of the large deviation muitifractal spectrum[C]. Rome: CFIC, 1996: 102-105.
[23]Levy Vehel J. Introduction to the multifractal analysis of imanes fractal image encoding and analysis [M].Springer Verfag: Y Fisher Editor, 1996:30-32
[24]Zhang M iugqin: The Safety Device and D iagnostic System for Tower Crane, Proceedings of Jmternational Comference on Advanced Technology and Equipment of Materials Handling, Beijing: China Machine Press, 1994:22-23
[25]刘佩衡．建筑塔吊市场预测及塔吊产品技术开发展望．建筑技术开发，1999(6)：42—50
[26]吴丽萍．我国起重机的新技术进展与国外发展动向．山西机械，2002(12)：51-55
[27]赵向阳，张宏，胡景清．工程机械控制系统的新发展．徐州工程机械，2003，2：59
[28]范俊祥．塔式起重机．中国建材工业出版社，2004，7：1-9，132-136
[29]孙在鲁．塔式起重机应用技术．中国建材工业出版社，2003，6：76-79
[30]CLAIMS JOHN SMTTB. Quslity is key to safety. CRANES TODAY, 1988(3):27 (2)
[31]Al-lami,B.J. (Inelec Inst);Benazzouz,,D. Microprocessor based crane load state monitoring system. IEE Conference Publication, v2, n332,1991,1183-1186
[32]Bernold, Leonhard E. (North Carolina State Univ):Lorenc, Steven J.:Luces, Erick. On-line assistance for crane operators. Journal of Computing in Civil Engineering, v11, n4,Oct, 1997, 248-259
[33]韦博军．塔式起重机力矩限制器技术状况的调查．建筑安全，1997(2)：9-10
[34]段为．塔式起重机力矩限制器的调试．建筑机械，1997(5)：28-30
[35]付剑雄．力矩限制器调整及系统综合精度计算．建筑机械，1996(9)12—20
[36]张炳义，王凤翔，冯桂宏．非接触式起重机力矩保护装置的改进．起重运输机械，1999(8)：26—28
[37]张炳义．新型非接触式起重机力矩保护装置．起重运输机械，1999(5)：28-30
[38]武建文，李德成．电机现代测试技术．机械工业出版社，2005：101—102
[39]张福学．传感器应用及其电路精选．北京：电子工业出版社，1993：90-92
[40]杨渝钦．控制电机．机械工业出版社，2001：109-117
[41]杨书华，霍孟友．微机原理及硬件接口技术．机械工业出版社，2004，1：228-286
[42]赵保经，罗振候，范敏等．A／D和D／A转换器应用手册．上海：上海科学普及出版社，1995：62—69
[43]王益全，张炳义．电机测试技术．科学出版社，2004：198-203
[44]王显正，陈正航．控制理论基础．北京国防工来出版社，1989．52—65
[45]王幸之等．单片机应用系统抗干扰技术．北京航空航天大学出版社，1999，12：347-375
[46]王庆斌，刘萍，尤利文．电磁干扰与电磁兼容技术．北京：机械工业出版社，1999：136-171
[47]陈伯时．电力拖动自动控制系统．机械工业出版社，2000，6：189—261