CN-121982839-A - Shackle safety load early warning device and detection method

CN121982839ACN 121982839 ACN121982839 ACN 121982839ACN-121982839-A

Abstract

The invention discloses a shackle safety load precaution device and a detection method, and aims to solve the problems that the existing shackle depends on manual experience or rated value control, cannot be monitored and precaution in real time, is low in integration level and is poor in data reliability. The early warning device comprises a shackle body, a built-in strain sensing assembly, a data acquisition module, a main control module, an early warning module and a wireless transmission module, wherein the built-in strain sensing assembly is arranged corresponding to a shackle stress concentration area to acquire strain signals, the data acquisition module is used for carrying out signal preliminary conditioning on the butting assembly, the main control module is used for converting the conditioned signals into load data through an integrated algorithm, the early warning module is used for receiving the load data to realize local and remote early warning, and the wireless transmission module is used for realizing data uploading and instruction receiving. The invention is suitable for the scenes of power construction, hoisting, power transmission line maintenance and the like, and can improve the shackle use safety and the management efficiency.

Inventors

TAO XIONGJUN
ZHAO QINGPENG
LIU DONGJIA
WANG YEFEI
LI CONG
LI BOJIE
ZHANG XUWEN
JIANG JINZHU
WANG YANGUO
ZHANG XIAOHUI

Assignees

中国南方电网有限责任公司超高压输电公司昆明局

Dates

Publication Date: 20260505
Application Date: 20251217

Claims (10)

1. The shackle safety load precaution device is characterized by comprising a shackle body, a built-in strain sensing assembly, a data acquisition module, a main control module, an precaution module and a wireless transmission module; the built-in strain sensing assembly is fixedly connected with the shackle body and is arranged in a stress concentration area of the shackle body under working conditions and used for collecting strain signals generated in the working process of the shackle body; the data acquisition module is electrically connected with the built-in strain sensing assembly and is used for receiving a strain signal output by the built-in strain sensing assembly and performing primary signal conditioning on the strain signal; the main control module is electrically connected with the data acquisition module, is integrated with the data processing algorithm unit, and is used for receiving the strain signal conditioned by the data acquisition unit, converting the strain signal into load data representing the stress state of the shackle body through the data processing algorithm unit, and generating an early warning instruction according to the comparison of the load data and the current threshold value; The early warning module is electrically connected with the main control module, and is used for receiving the early warning instruction transmitted by the main control module and making early warning action according to the early warning instruction; The wireless transmission module is electrically connected with the main control module and is used for receiving the load data transmitted by the main control module, transmitting the load data to the external background monitoring platform, receiving the threshold adjustment instruction issued by the external background monitoring platform in real time and feeding back the threshold adjustment instruction to the main control module.
2. The shackle safety load precaution device according to claim 1, wherein the built-in strain sensing assembly comprises a strain gauge and a protection-resistant packaging layer, the strain gauge is fixed with a stress concentration area of the shackle body through colloid, and the protection packaging layer covers the surface of the strain gauge and the connection part of the strain gauge and the shackle body.
3. The shackle safety load precaution device according to claim 1, wherein the data acquisition unit is a stress acquisition module, the stress acquisition module is provided with a signal input channel, receives a strain signal output by the built-in strain sensing assembly, and performs signal amplification and filtering processing according to the strain signal.
4. The shackle safety load precaution device according to claim 1, wherein the data processing algorithm module comprises a filtering unit, a calibration unit, a temperature compensation unit and a stress load conversion unit, wherein the filtering unit is used for removing interference components in the strain signal, the calibration unit is used for carrying out precision calibration on the strain signal after filtering, the temperature compensation unit is used for eliminating the influence of environmental temperature change on the strain signal, and the stress load conversion unit is used for converting the processed strain signal into load data.
5. The shackle safety load precaution device according to claim 1, wherein the precaution module comprises a local indicator light module and a remote alarm module, wherein the local indicator light module is arranged on the outer side of the shackle body and presents the load condition of the shackle body according to the lighting state of the light; The remote alarm unit is arranged inside the main control module, can generate an alarm signal when the load data reaches a preset threshold value, transmits the alarm signal to the wireless transmission module, and then transmits the alarm signal to the external background monitoring platform through the wireless transmission module.
6. The shackle safety load precaution device according to claim 1, wherein the data processing algorithm unit in the main control module is further integrated with a dynamic threshold adjustment subunit, the dynamic threshold adjustment subunit comprising: generating an initial threshold based on a preset rated load of the shackle body, the stress concentration area characteristic determined by the three-dimensional finite element simulation model and a safe stress fluctuation range in historical load data; receiving a threshold adjustment instruction fed back by the wireless transmission module and issued by an external background monitoring platform according to different working conditions, and dynamically correcting the initial threshold to obtain a target threshold adapting to the current working condition; And comparing the target threshold value with the load data converted in real time, transmitting a first-level early warning instruction to the early warning module when the load data reaches the target threshold value, and transmitting a second-level early warning instruction to the early warning module when the load data reaches or exceeds the target threshold value.
7. The shackle safety load precaution device according to claim 1, wherein a detachable connection structure is provided on the shackle body, and the built-in strain sensing assembly, the data acquisition module, the main control module, the precaution module and the wireless transmission module are all connected with the shackle body through the detachable connection structure.
8. The method for detecting the right shackle safety load early warning is applied to the shackle safety load early warning device as claimed in claims 1 to 7, and is characterized by comprising the following steps: Performing signal amplification and filtering treatment on the original strain signal to finish signal preliminary conditioning; Carrying out algorithm processing on the preliminarily conditioned signals to generate load data representing the real-time stress state of the shackle; Judging whether to trigger early warning according to a comparison result of the load data and a preset safety threshold; And sending the processed load data to a visual interface for real-time display, and generating early warning information when triggering early warning.
9. The method for detecting the shackle safety load early warning according to claim 8, further comprising the step of carrying out stress analysis on the shackle body, wherein the step of: constructing a three-dimensional simulation model of the shackle body, simulating stress conditions of the shackle body under different working conditions, and determining a primary stress concentration area to obtain simulation analysis data; And verifying the stress concentration area according to an actual load experiment, obtaining stress data, comparing the stress data with the simulation analysis data, and correcting and determining the final stress concentration area for arranging the built-in strain sensing assembly.
10. The method of claim 8, wherein triggering the early warning includes simultaneously activating a local indicator light alarm and sending an early warning signal to a remote monitoring platform.

Description

Shackle safety load early warning device and detection method Technical Field The invention relates to the technical field of safety monitoring of hoisting equipment, and particularly provides a shackle safety load precaution device and a detection method. Background In various lifting, hoisting and mooring operations, the shackle is used as a key bearing connecting piece, and the safety and reliability of the shackle are directly related to the life safety of the whole operation system and even personnel. However, the conventional shackle products belong to passive mechanical components, and generally lack real-time sensing and monitoring capabilities for stress states of the conventional shackle products, so that on-site operators are difficult to dynamically grasp actual load changes of the conventional shackle products, and cannot provide prognosis for potential overload risks. Some existing improvement technologies attempt to realize the monitoring function by adding an external sensing device, but the solutions often have the problems of complex installation process and low integration level. The sensor and the shackle body are in a separated state, so that the portability of equipment is affected, signal transmission is easily interfered by complex electromagnetic environment and mechanical vibration on site, and the accuracy and reliability of monitoring data are greatly reduced. In addition, the data processing capability of such devices is generally weak, and the devices lack effective signal processing algorithms for denoising, compensating and accurately converting the original data, and also lack visual data visualization support. The result is that early warning information is often lagged, immediate and definite local and remote warning cannot be provided when the load is critical, clear and visual stress guidance is difficult to provide for field operators, and finally the effectiveness of safety monitoring cannot reach the expectations, so that a remarkable safety management short board exists. Therefore, a novel monitoring scheme with high integration, real-time accuracy and intelligent early warning capability is urgently needed in the industry. Disclosure of Invention The technical problem that in the prior art, the shackle and the monitoring device thereof cannot realize real-time and accurate monitoring and early warning of load conditions is solved. The invention provides a shackle safety load precaution device and a detection method. The invention provides a shackle safety load precaution device, which comprises a shackle body, a built-in strain sensing assembly, a data acquisition module, a main control module, an precaution module and a wireless transmission module; the built-in strain sensing assembly is fixedly connected with the shackle body and is arranged in a stress concentration area of the shackle body under working conditions and used for collecting strain signals generated in the working process of the shackle body; the data acquisition module is electrically connected with the built-in strain sensing assembly and is used for receiving a strain signal output by the built-in strain sensing assembly and performing primary signal conditioning on the strain signal; the main control module is electrically connected with the data acquisition module, is integrated with the data processing algorithm unit, and is used for receiving the strain signal conditioned by the data acquisition unit, converting the strain signal into load data representing the stress state of the shackle body through the data processing algorithm unit, and generating an early warning instruction according to the comparison of the load data and the current threshold value; The early warning module is electrically connected with the main control module, and is used for receiving the early warning instruction transmitted by the main control module and making early warning action according to the early warning instruction; The wireless transmission module is electrically connected with the main control module and is used for receiving the load data transmitted by the main control module, transmitting the load data to the external background monitoring platform, receiving the threshold adjustment instruction issued by the external background monitoring platform in real time and feeding back the threshold adjustment instruction to the main control module. Further, the built-in strain sensing assembly comprises a strain gauge and a protective packaging layer, wherein the strain gauge is fixed with a stress concentration area of the shackle body through colloid, and the protective packaging layer covers the surface of the strain gauge and the connection part of the strain gauge and the shackle body. Further, the data acquisition unit is a stress acquisition module, the stress acquisition module is provided with a signal input channel, receives a strain signal output by the built-in strain sensing assembly, and perf