Research On FBG-sensor-based Structural Health Monitoring And Safety Warning System Of MQ2533Gantry Crane

Though crane acts as the fundamental role in the operation of major industrialenterprises, its security issue faces grim situations and challenges for serious accidentsstill occur. So far, the maintenance of crane has still been employing the policy of‘regular maintenance, posterior maintenance’ and Two-year regular inspection byQuality Inspection Departments for crane safety assurance in China, which means it islack of large crane structural health monitoring and early warning technology.Therefore, we need to propose a targeted measure to prevent such incidents occurredagain. Therefore, doing the Research work on FBG-Sensor-Based Structural HealthMonitoring and Safety Warning System of MQ2533Gantry Crane has profoundpractical significance.This subject was originated from the science and technology project of StateQuality Inspection Administration ‘Crane Structural Health Monitoring and EarlyWarning System based on the Internet of Things’(NO.2012QK069).This paper aims at developing a set of FBG-Sensor-Based Structural HealthMonitoring and Safety Warning System of MQ2533Gantry Crane. The main contentsinclude:1) The basic principle of structural health monitoring was described. Accordingto the research background and overseas and domestic Research Status, wesummarized this subject from four aspects: the technology of computer graphics andimage processing technology, the technology of stress and strain distribution, thetechnology of fiber optic acoustic emission, the technology of structural vibrationanalysis. Then the overall study situation of structural health monitoring waselaborated.2) Research on the acquisition of the history of the falut information. As it showsin the historical data, gantry crane will have significant fault occurs if they have beenworked about15years and the fault failure mainly in the form of crack, deformationand corrosion-based. It is necessary to establish a Structural Health Monitoring tomonitor these positions.3）Put forward the overall design of structural health monitoring and earlywarning system. The system is divided into hardware part and software part. Thehardware part contains metal structure stress information obtaining and sensordistribution program designing; the software part contains software platform developing, warning threshold and alarm threshold scheme setting, real-timenetworking and historical data storing achieving.4) Analyse the sensor performance of the structural health monitoring and earlywarning system hardware part. We used four kinds of sensors to do a tensile test:BGK-FBG-4150sensor, FLA-5-11strain sensor, American MOI FBG sensor andwireless strain sensor. Based on the data of FLA-5-11which was calibrated byGuangzhou Institute of Measuring and Testing Technology, we have tested theaccuracy of the other three type of sensors. As it shows in the experimental results,the error rate of MOI os3110FBG sensors and BGK-FBG-4150sensors were within10%. Taking cost-effective into account, BGK-FBG-4150sensors were finally used inthe SHM and Early warning System.5) Research on the number and location optimized scheme of FBG sensors of thestructural health monitoring and early warning system. Taking MQ2533gantry craneas an example, in the condition of minimum amplitude(magnitude9.5m) andmaximum amplitude(magnitude33m) of the MQ2533Gantry Crane, the simulationand modeling work was did. According to the work characteristics of MQ2533andtaking into account of the stress cloud of the bridge of the nose, balance beam, largerod, A-frame and slewing platform, the distribution scheme was finally obtained. Wedecided to use15channels, a total of32FBG strain and temperature sensors toconduct the real-time monitoring of the MQ2533gantry crane. Then the weldingequipment and welding process of BGK-FBG-4150were introduced.6) Develop a software platform of the Structural health monitoring and earlywarning system. Then the specific program and threshold setting method of thesystem was designed. In addition, I developed the software platform and touch-screeninterface software platform of the system. Because of the cross-sensitive issues ofFBG sensors, we deduced the basic formula of BGK-FBG-4150and obtained thelinear fitting formula of Temperature and Strain Sensors in order to calculate thereal-time stress of the MQ2533in the software platform. Finally, on-site installationand application was carried out.