CN-121993456-A - Anti-leakage system and method for hydraulic station of quay crane

CN121993456ACN 121993456 ACN121993456 ACN 121993456ACN-121993456-A

Abstract

The invention belongs to the technical field of a leakage prevention system of a hydraulic station of a rear girder of a shore bridge, and particularly relates to a leakage prevention system and method of the hydraulic station of the shore bridge. The hydraulic station comprises a data acquisition module, a data processing and control module and a data processing and control module, wherein the data acquisition module is used for acquiring an oil tank liquid level signal of a hydraulic station of a shore bridge and at least one real-time working condition signal of the shore bridge in real time, and the data processing and control module is electrically connected with the data acquisition module. The invention effectively distinguishes liquid level fluctuation and real leakage caused by normal actions of equipment (such as movement of a cart and action of an oil cylinder), and fundamentally solves the problems of high false alarm rate and alarm lag of the traditional low liquid level alarm device.

Inventors

CHEN PEI
ZHANG SHUAI
ZHANG KAI
ZHANG PENG
MA CANCAN

Assignees

天津港第二集装箱码头有限公司

Dates

Publication Date: 20260508
Application Date: 20260203

Claims (9)

1. A shore bridge hydraulic station leak protection system, comprising: The data acquisition module is used for acquiring an oil tank liquid level signal of the hydraulic station of the shore bridge and at least one real-time working condition signal of the shore bridge in real time; the data processing and control module is electrically connected with the data acquisition module and is configured to: receiving the oil tank liquid level signal and the real-time working condition signal; Judging the current operation scene of the quay bridge based on the real-time working condition signal; According to the operation scene, a corresponding preset liquid level change logic model or rule is called; Comparing and analyzing the change trend of the liquid level of the oil tank obtained in real time with the preset liquid level change logic model or rule; And when the change trend of the liquid level of the oil tank does not accord with the preset logic or rule corresponding to the current operation scene and is continuously descending, generating a leakage alarm signal.
2. The shore bridge hydraulic station leak protection system of claim 1, wherein said real-time operating condition signals include one or more of a speed or acceleration signal of a cart drive motor, a speed signal of a pitch drive motor, a displacement or speed signal of a tilt cylinder, and a equipment hanging fault signal.
3. The shore bridge hydraulic station leak protection system of claim 2, wherein when said real-time condition signal indicates that the shore bridge is in a cart moving state, said preset liquid level change logic model is: calculating a theoretical maximum liquid level fluctuation range (delta h_max) allowed under the current acceleration according to the real-time collected horizontal acceleration (a) of the cart, the length (L) of the oil tank along the movement direction of the cart and a preset correction coefficient; Comparing the real liquid level variation (deltah_actual) of the adjacent period monitored in real time with the theoretical maximum liquid level fluctuation amplitude (deltah_max); If the actual liquid level variation does not continuously exceed the theoretical maximum fluctuation range and the liquid level is in fluctuation, the liquid level is judged to be normal, if the actual liquid level variation continuously exceeds the theoretical maximum fluctuation range, the early warning is triggered, and if the liquid level variation is continuously reduced, the leakage alarm signal is generated.
4. The shore bridge hydraulic station leak prevention system according to claim 3, wherein the theoretical maximum liquid level fluctuation width (Δh_max) is calculated by a formula of Δh_max= (l×a×k)/(2 g), where k is a damping correction coefficient set based on hydraulic oil characteristics, and g is gravitational acceleration.
5. The shore bridge hydraulic station leak protection system of claim 2, wherein when said real-time condition signal indicates that one or more tilt cylinders are operating, said preset rules are: in the time period of the action of the tilting oil cylinders, the liquid level change of the oil tank monitored in real time is smaller than or equal to the liquid level maximum theoretical difference value (X) between all the tilting oil cylinders in all extending and all retracting states; If the rule is satisfied, the rule is judged to be normal.
6. The shore bridge hydraulic station leak protection system of claim 2, wherein upon receiving a device hanging fault signal, the data processing and control module determines that the level change is normal if an instantaneous rise in the tank level is monitored.
7. The shore bridge hydraulic station leak protection system of claim 2, wherein when said real-time condition signal indicates that at least one of a trolley, a lifting or a pitching mechanism is in motion and no hanging bin fault signal is received, said preset rule is: monitoring whether the liquid level of the oil tank presents fluctuation or not rather than continuous decline in the action time period of the corresponding mechanism; If yes, judging as normal.
8. The shore bridge hydraulic station leak protection system according to any one of claims 1 to 7, wherein the data acquisition module comprises an ultrasonic liquid level sensor mounted on an oil tank, and a sensor or interface circuit for acquiring each working condition signal, and the data processing and control module is a Programmable Logic Controller (PLC).
9. A method of preventing leakage in a hydraulic station of a quay crane, applied to a system as claimed in any one of claims 1 to 8, the method comprising: acquiring a liquid level signal of an oil tank and a real-time working condition signal of a shore bridge in real time; Identifying the current operation scene of the quay bridge according to the real-time working condition signal; Invoking preset liquid level change judging logic matched with the current operation scene; Analyzing compliance of the real-time liquid level signal under the judgment logic; if the analysis result shows that the liquid level change is not compliant and continuously decreases, the leakage is judged to occur and the alarm is given.

Description

Anti-leakage system and method for hydraulic station of quay crane Technical Field The invention belongs to the technical field of a leakage prevention system of a hydraulic station of a rear girder of a shore bridge, and particularly relates to a leakage prevention system and method of the hydraulic station of the shore bridge. Background In container terminal loading and unloading operations, a quay (quay container crane) is one of the core devices, and stable and reliable operation of a hydraulic system (particularly a rear girder hydraulic station) is crucial. The hydraulic system is responsible for driving various key actions such as lifting and tilting of the quay bridge, trolley walking, bracket tensioning and the like, once leakage occurs, hydraulic oil waste and environmental pollution are caused, equipment failure, action misalignment and even safety accidents are more likely to be caused due to insufficient oil pressure, and the working efficiency and safety of a wharf are seriously affected. At present, the technical scheme commonly adopted in the aspect of leakage prevention of a rear girder hydraulic station of a shore bridge in the industry is that a set of simple low-liquid-level alarm device is arranged on a hydraulic oil tank. The device typically includes a float or capacitive level sensor and sets a fixed low level threshold. When the oil level in the oil tank falls below the threshold value, the sensor triggers an alarm signal to inform maintenance personnel to check. However, the conventional leakage prevention method has obvious technical defects and limitations that 1, in order to prevent false alarm caused by short fluctuation of the oil level due to normal working conditions such as equipment inclination and vibration, the liquid level alarm threshold value is usually set to be low. This means that the system will only alert if there is a lot of oil in the tank that has leaked and is left. At this point, the leak often has lasted for a longer period of time, may have caused increased intake, component wear or abnormal operation of the hydraulic system, and has lost the opportunity for early warning and intervention. 2. If the alarm threshold is tried to be properly improved to realize early warning, false alarm is triggered easily due to various normal oil level fluctuation generated in the operation process of the shore bridge. For example, the inertia of a quay crane cart as it moves causes a significant change in the tank level, such as sloshing of the oil, redistribution of the oil within the system as each actuator (e.g., tilt cylinder, cart hydraulic motor) is actuated, and impact when the equipment "hangs up" from the tank. The existing simple alarm device cannot intelligently distinguish normal and transient oil level fluctuation from continuous leakage drop, so that frequent false alarm is caused, normal production order is disturbed, and maintenance personnel generate alarm fatigue, so that real dangerous situations are ignored. 3. The prior art is only an isolated threshold comparison and is not related to real-time operation states (such as motor speeds, cylinder displacement, fault signals and the like) of the quay crane. The system cannot know what action is currently being performed by the device and thus cannot determine whether the observed oil level change coincides with the theoretical impact of that action. This results in all drops below the non-threshold being ignored or false positive uniformly, with a low level of intelligentization. 4. Because of the problem of inaccurate early warning and positioning, maintenance personnel must frequently attend to the scene to verify the authenticity of the alarm and check the leakage point. This not only increases unnecessary labor intensity and maintenance costs, but also increases fault response and handling time. In summary, the existing anti-leakage technology of the hydraulic station of the quay crane has the problems of untimely alarm, high false alarm rate, insufficient intelligent degree and low maintenance efficiency. Disclosure of Invention The invention aims to provide a shore bridge hydraulic station leakage prevention system and a shore bridge hydraulic station leakage prevention method, which are used for solving the problems in the background technology. In order to achieve the purpose, the invention provides the following technical scheme that the anti-leakage system of the hydraulic station of the quay crane comprises: The data acquisition module is used for acquiring an oil tank liquid level signal of the hydraulic station of the shore bridge and at least one real-time working condition signal of the shore bridge in real time; the data processing and control module is electrically connected with the data acquisition module and is configured to: receiving the oil tank liquid level signal and the real-time working condition signal; Judging the current operation scene of the quay bridge based on the real-t