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基于多传感器融合的堆垛机状态监控系统设计

Design of a multisensor-fusion-based condition monitoring system for stacker cranes

  • 摘要: 为解决烟草企业仓储物流系统中因堆垛机发生故障而导致的生产效率低、财产损失大等问题,设计了一种基于多传感器融合的堆垛机状态监控系统。在堆垛机上安装振动/温度传感器、倾角传感器、激光位移传感器和摄像头,实时监测堆垛机的姿态及货叉与托盘的位置,并依托无线通信技术高速传输监测数据;选择关键传感器的监测数据作为健康状态评价指标,使用CRITIC权重法对堆垛机的振动、倾角、货叉高度等多维运行数据进行融合分析,构建堆垛机健康状态综合评估模型以量化评估设备健康度;开发堆垛机运行状态监测平台,实现对关键部件状态和健康度信息的可视化展示,提示工人及时进行预防性维修和保养。以黄金叶生产制造中心使用的堆垛机为应用对象进行现场验证,结果表明:监控系统投入运行后,堆垛机故障率由0.63%降至0.45%,月均停机时间由230 min/台降至168 min/台,有效避免物料掉落5次/月。该系统可为提升仓储作业的安全性提供技术支持。

     

    Abstract: To address reduced production efficiency and substantial property losses caused by stacker crane failures in the warehousing and logistics systems of tobacco enterprises, a multi-sensor-fusion-based condition monitoring system for stacker cranes was designed. Vibration/temperature sensors, tilt angle sensors, laser displacement sensors, and cameras were installed on the stacker cranes to monitor the stacker crane orientation and the fork pallet positions in real time, while the monitoring data were transmitted at a high speed through wireless communication technology. Monitoring data from key sensors were selected as health status evaluation indicators, and the CRITIC weighting method was used to assign weights and fuse multidimensional operating data, including stacker crane vibration, tilt angle and fork height. A comprehensive health status assessment model was developed to quantitatively evaluate equipment health. A operating condition monitoring platform for stacker cranes was developed to visualize the operating condition and health status of key components and to prompt operators to perform preventive maintenance in a timely manner. On-site verification was carried out on the stacker cranes in Golden Leaf Production and Manufacturing Center. The results showed that, after the designed monitoring system was put into operation, the stacker crane failure rate decreased from 0.63% to 0.45%, the average monthly machine downtime from 230 min/unit to 168 min/unit, and the frequency of material drop incidents by five times per month. The system provides technical support for improving the safety of warehousing operations.

     

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