起重机激光检测仪的研制
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摘要
起重机械是用来对物料起重、运输、装卸和安装等作业的机电设备,广泛应用于冶金、机械制造和建材等工业生产中。然而,设计缺陷、制造缺陷、长期超载荷作业或使用不当等原因都会使起重机械毁坏,造成工程停滞甚至人员伤亡等后果,所以起重机被列为特种设备,需要特殊检测与管理。但是目前由于缺少用于起重机安全检测的专用高精度仪器,致使起重机安全检测效率低下,因此,研发安全、高效、智能的起重机安全检测专用仪器具有非常重要的现实意义和社会价值。
论文在分析与对比现有起重机安全检测方法的基础上,结合当前主流起重机的结构特点,提出了起重机激光检测仪的测量原理和技术方案,并对方案的技术可行性、关键点和难点进行了理论分析,进而提出系统方案。总系统分为机械结构系统、检测硬件系统及检测软件系统三大模块。
在机械结构系统设计中,依据总体技术要求制定了机械系统的总体方案,并给出各部套的功能和特点。其中,重点对机械结构中三轴关系及对系统精度的影响进行了理论分析,通过工程图纸设计、三维造型和仿真分析等手段,提出了后续的加工、组装及精度补偿方法。在检测硬件系统设计中,从测量原理及方案出发,进行了检测系统总体方案设计。从实现功能的原理入手,对激光测距传感器、核心芯片等光、电模块及元器件进行了选型设计及相关的接口设计,进而研制了检测硬件系统的原理样机。在检测软件系统设计中,制定了软件系统方案,对主程序、定时模块、数据分析程序等进行具体的设计开发,完成了整套的嵌入式软件。通过三大模块的研制,进行系统组装和联调,并按已制定的系统校准方案,对该检测仪进行了初步校准。为了检验该检测仪的性能,先在室内进行定点验证测试,进而在起重机现场进行检测试验。从检测精度和检测效率两方面,对该检测仪和特种设备检测院采用的通用检测仪的测量数据进行了对比分析,结果显示该仪器能满足起重机安全检测的精度要求,且检测效率较之前也大大提高。
论文最后总结了该仪器目前存在的问题,并对该仪器今后性能的完善和提高等方面,提出了相应的技术措施与方法途径。
本文所述的起重机激光检测仪,具有操作简便、检测效率高、智能化等特点,可满足市场需求。同时,也对其它类似仪器的研制具有较好的参考价值。
Lifting appliance is a kind of electromechanical equipment used for lifting, transiting, loading or unloading and installing objects, which is widely applied in the industries such as metallurgy, mechanical manufacturing and building materials. However, the factors such as the defects in design and manufacturing, doing long-term overloading jobs as well as improper operation may all cause injuries to lifting appliances, and all these may bring cease to the engineering project or even loss of lives and personal injuries. As for these reasons, crane is listed as special equipment requiring special test and management. Currently, for lack of specialized high-precision equipments used for security detection of cranes, the security detection efficiency is very low. Therefore, it has greatly significant practical significance and social value to research and develop safe, efficient and intelligent specialized security detection instruments used in cranes.
The thesis is based on the analysis and comparison of the approaches of current security detection of cranes. It combines the structure characteristic of the existing mainstream cranes, and then proposes the principle of measurement and technical plan of the laser detectors used in cranes, which also conducts theoretical analysis about the plan’s technical feasibility, key points and difficulties so as to propose system programs. The total system is divided into three modules; they are the mechanical structure system, the hardware system and the software system used for detection.
When designing the mechanical structure system, according to the overall technical request it draws up the overall plan of the mechanical system and tells different functions and characteristics of different components. In this part, it emphasizes on the theoretical analysis of the impact that the relationship of the three axes in mechanical structure has on the system precision. Through drawings of engineering design, 3D solid modeling and simulation analysis, it gives subsequent approaches in processing, assembling and installing as well as the precision compensation. When designing the hardware system used for detection, it begins with the principle of measurement and the program designing the overall program of the detection system. It starts at the principle of realizing the function, and then conducts lectotype design and relative interface design about distance laser sensor, photoelectricity module and components such as core chips, and so on. And a PCBA is designed finally for the detection hardware system. When designing the detection software system, it draws up the software system program, designing and developing specifically about the main program, timing module, as well as data analysis program, so as to finish the whole embedded software. After researching and developing the three modules, the total system is assembled joint debugged, and the preliminary calibration is done to the detector according to the system calibration plan that has been made. In order to test the properties of this detector, a fixed-point checking test is firstly done indoor, and then doing spot test at the work site. Comparisons and analysis about the testing data are conduct between the detector designed and the common-use detectors used by Special Equipment Inspection Institute. Result shows that the detector designed can satisfy the prevision request of crane’s security detection, and the detection efficiency is increased greatly.
The thesis at last summarizes the existing problems about this instrument and proposes relative technical measurement and approaches to improve the properties of the instrument designed.
The laser detector used in cranes designed in this thesis is characterized with easy operation, high efficiency in detection and intelligentize, which finely meet the requirement of the market. Meanwhile, it obtains great reference value to the research and development of other similar instruments.
论文在分析与对比现有起重机安全检测方法的基础上,结合当前主流起重机的结构特点,提出了起重机激光检测仪的测量原理和技术方案,并对方案的技术可行性、关键点和难点进行了理论分析,进而提出系统方案。总系统分为机械结构系统、检测硬件系统及检测软件系统三大模块。
在机械结构系统设计中,依据总体技术要求制定了机械系统的总体方案,并给出各部套的功能和特点。其中,重点对机械结构中三轴关系及对系统精度的影响进行了理论分析,通过工程图纸设计、三维造型和仿真分析等手段,提出了后续的加工、组装及精度补偿方法。在检测硬件系统设计中,从测量原理及方案出发,进行了检测系统总体方案设计。从实现功能的原理入手,对激光测距传感器、核心芯片等光、电模块及元器件进行了选型设计及相关的接口设计,进而研制了检测硬件系统的原理样机。在检测软件系统设计中,制定了软件系统方案,对主程序、定时模块、数据分析程序等进行具体的设计开发,完成了整套的嵌入式软件。通过三大模块的研制,进行系统组装和联调,并按已制定的系统校准方案,对该检测仪进行了初步校准。为了检验该检测仪的性能,先在室内进行定点验证测试,进而在起重机现场进行检测试验。从检测精度和检测效率两方面,对该检测仪和特种设备检测院采用的通用检测仪的测量数据进行了对比分析,结果显示该仪器能满足起重机安全检测的精度要求,且检测效率较之前也大大提高。
论文最后总结了该仪器目前存在的问题,并对该仪器今后性能的完善和提高等方面,提出了相应的技术措施与方法途径。
本文所述的起重机激光检测仪,具有操作简便、检测效率高、智能化等特点,可满足市场需求。同时,也对其它类似仪器的研制具有较好的参考价值。
Lifting appliance is a kind of electromechanical equipment used for lifting, transiting, loading or unloading and installing objects, which is widely applied in the industries such as metallurgy, mechanical manufacturing and building materials. However, the factors such as the defects in design and manufacturing, doing long-term overloading jobs as well as improper operation may all cause injuries to lifting appliances, and all these may bring cease to the engineering project or even loss of lives and personal injuries. As for these reasons, crane is listed as special equipment requiring special test and management. Currently, for lack of specialized high-precision equipments used for security detection of cranes, the security detection efficiency is very low. Therefore, it has greatly significant practical significance and social value to research and develop safe, efficient and intelligent specialized security detection instruments used in cranes.
The thesis is based on the analysis and comparison of the approaches of current security detection of cranes. It combines the structure characteristic of the existing mainstream cranes, and then proposes the principle of measurement and technical plan of the laser detectors used in cranes, which also conducts theoretical analysis about the plan’s technical feasibility, key points and difficulties so as to propose system programs. The total system is divided into three modules; they are the mechanical structure system, the hardware system and the software system used for detection.
When designing the mechanical structure system, according to the overall technical request it draws up the overall plan of the mechanical system and tells different functions and characteristics of different components. In this part, it emphasizes on the theoretical analysis of the impact that the relationship of the three axes in mechanical structure has on the system precision. Through drawings of engineering design, 3D solid modeling and simulation analysis, it gives subsequent approaches in processing, assembling and installing as well as the precision compensation. When designing the hardware system used for detection, it begins with the principle of measurement and the program designing the overall program of the detection system. It starts at the principle of realizing the function, and then conducts lectotype design and relative interface design about distance laser sensor, photoelectricity module and components such as core chips, and so on. And a PCBA is designed finally for the detection hardware system. When designing the detection software system, it draws up the software system program, designing and developing specifically about the main program, timing module, as well as data analysis program, so as to finish the whole embedded software. After researching and developing the three modules, the total system is assembled joint debugged, and the preliminary calibration is done to the detector according to the system calibration plan that has been made. In order to test the properties of this detector, a fixed-point checking test is firstly done indoor, and then doing spot test at the work site. Comparisons and analysis about the testing data are conduct between the detector designed and the common-use detectors used by Special Equipment Inspection Institute. Result shows that the detector designed can satisfy the prevision request of crane’s security detection, and the detection efficiency is increased greatly.
The thesis at last summarizes the existing problems about this instrument and proposes relative technical measurement and approaches to improve the properties of the instrument designed.
The laser detector used in cranes designed in this thesis is characterized with easy operation, high efficiency in detection and intelligentize, which finely meet the requirement of the market. Meanwhile, it obtains great reference value to the research and development of other similar instruments.
引文
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[29]陈赟.单圈绝对式光电轴角编码器原理的研究[D].长春:中国科学院长春光学精密机械与物理研究所,2006.
[30]赵长海,万秋华,王树洁等. 21位光电编码器数据处理系统[J].电子测量与仪器学报,2010(6):569-573.
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[3]肖立群.日本起重机安全管理的现状[J].起重运输机械,2000(11):3-7.
[4]梁广炽.美国起重机械安全管理概述[J].中国质量技术监督,2007(4):54-55.
[5]须雷,王福绵,董尚元.国内外起重机械标准法规比较手册[M].北京:中国标准出版社,2009.
[6] TSG Q7016-2008.起重机械安装改造重大维修监督检验规则[S].北京:新华出版社,2008.
[7] TSG Q7015-2008.起重机械定期检验规则[S].北京:新华出版社,2008.
[8]郭强.桥架类型起重机结构疲劳强度研究[D].武汉:武汉理工大学,2009,29-59.
[9]管红绢.嵌入式技术在起重机在安全监控系统中的应用[D].安徽:安徽理工大学,2009,15-30.
[10]沈功田,戴光,刘时风.中国声发射检测技术进展--学会成立25周年纪念.无损检测,2003(6):302-307.
[11] K. F. Hale. An optical - fiber fatigue crack detection and monitoring system [J]. SPIE ,1992 ,1777 :147~150.
[12] D. C. Lee, et al. Monitoring of fatigue crack growth in steel structures using intensity - based optical fiber sensors [J]. Journal of Intelligent Material Systems and Structures, 2000 ,11 :100~107.
[13] K. Ichinose, et al. Detection of the failure zone caused by cyclic loading [J]. Journal of Intelligent Material Systems and Structures , 1999 ,10 :214~220.
[14] Belleville C, Dupain G. White-light interferometric multimode fiber-optic strain sensor[J]. Optics Letters.1993,18(1):78 -80.
[15] Ettouney M and et al. Health Monitoring of Complex Structures[J]. SPIE,1998,(3326) : 368-379.
[16] Kazuro Kageyama and et al. Smart marine structures: an approach to the monitoring of ship structures with fiber-optic sensors[J]. Smart Mater Struct.1998,(7):472- 478.
[17] SEAH S.A Co.,Ltd. Crane Monitoring System. http://www.tradekorea.com/.
[18] Horsburgh & Scott Co,.Ltd. Sentry Wireless Crane Monitoring System. http://www.horsburgh-scott.com/.
[19]吴占稳,沈功田,王少梅.声发射技术在起重机无损检测中的现状[J].起重运输机械,2007(10):1-4.
[20]沈功田,耿荣生,刘时风.声发射信号的参数分析[J].无损检测,2002(2):72-77.
[21]李力,陈向前,赵美云等.起重机梁活性缺陷的声发射信号特征[J].无损检测,2008(6):334-337.
[22]陈黎峰.桥(门)式起重机主梁上拱度和挠度的测量分析[J].装备制造与技术,2010(5):124-125.
[23]闫心一.钢丝自重对测量桥式起重机主梁上拱度影响的修正值的计算[J].港口装卸,2001(4):16-18.
[24]许忠福.在用电动单梁起重机上拱度检验方法的探讨[J].起重运输机械,2008(2):92-93.
[25]陈成.浅谈激光测距仪在起重机检验中的应用[J].中小企业管理与科技,2010(27):116.
[26]刘敬东,程红星,运向勇等.激光测距仪在起重机检测中的运用[J].起重运输机械,2008(9):58-60.
[27]汪友生,徐小平.相位法激光测距的实现[J].北京工业大学学报,2003(4):424-427.
[28]贾方秀,丁振良,袁锋.相位法激光测距接收系统[J].光学精密工程,2009(10):2377-2384.
[29]陈赟.单圈绝对式光电轴角编码器原理的研究[D].长春:中国科学院长春光学精密机械与物理研究所,2006.
[30]赵长海,万秋华,王树洁等. 21位光电编码器数据处理系统[J].电子测量与仪器学报,2010(6):569-573.
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