CN102398868A - Intelligent tower crane monitoring system - Google Patents

Intelligent tower crane monitoring system Download PDF

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Publication number
CN102398868A
CN102398868A CN2011103723047A CN201110372304A CN102398868A CN 102398868 A CN102398868 A CN 102398868A CN 2011103723047 A CN2011103723047 A CN 2011103723047A CN 201110372304 A CN201110372304 A CN 201110372304A CN 102398868 A CN102398868 A CN 102398868A
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tower
module
sensor
tower machine
seconds
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CN102398868B (en
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徐惠余
肖友刚
杨红立
樊智明
程新中
陈果
张磊
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Jianglu Electromechanical Science & Technology Co Ltd
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Jianglu Electromechanical Science & Technology Co Ltd
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Abstract

The invention relates to an intelligent tower crane monitoring system, which comprises a control box (1), a display screen (2), an altitude sensor (3), an amplitude sensor (4) and a weight sensor (5), the control box and the display screen are mounted in the control room of the cab of a tower crane, the altitude sensor is mounted on a lifting mechanism, the amplitude sensor is mounted on a luffing mechanism, the weight sensor is mounted in the proving ring shaft of the tower crane, and each sensor is connected with the control box (1) through a cable. The system can carry out high-precision, high-reliability monitoring and control on the tower crane.

Description

Tower is quick-witted can monitored control system
Technical field
Present technique relates to a kind of tower crane safety monitoring device, is a kind of universal tower machine safety intelligence monitoring and controlling device that is applicable to various model tower machines, need not programmer's participation.
Background technology
Be the operation information of monitoring tower machine, occurred multiple tower machine monitor in the market.And these tower machine monitors have all embedded the geometric parameter, alarm limit parameter, hoisting moment characteristic of particular column machine etc. in kernel program, so certain tower machine monitor can only be used in the tower machine of certain model, lack commonality and extensibility.
And, in the tower machine monitor that has occurred, mostly be that output-controlling device is also linked controller by lead with micro controller system, Programmable Logic Controller or embedded system configuration corresponding data acquisition channel, the instrument circuit more complicated also is not easy to the function expansion like this.
The tower machine is a kind of construction machinery and equipment of mobile operation, and variation of ambient temperature is big, and monitoring accuracy is high in this environment, and then performance significantly degenerates in another environment.
Summary of the invention
To the defective of existing tower machine monitoring appearance shortage commonality, extensibility, the present invention has announced a cover high precision, modular universal tower machine monitoring device, realizes the high precision of tower crane, the monitoring and the control of high reliability.The temperature of elimination sensor is floated the influence with creep, improves monitoring accuracy.
Present technique relates to a kind of universal tower crane intelligent monitored control system; This system comprises control capsule 1, read-out 2, height sensor 3, amplitude sensor 4, weight sensor 5; Wherein control capsule and read-out are installed in the tower machine operator's compartment control cabin, and height sensor is installed on the lifting mechanism, and the amplitude sensor is installed on the luffing mechanism; Weight sensor is installed in the tower machine dynamometry annulate shaft, and each sensor is connected with control capsule through cable.
This system adopts modular design, comprising: embedded main board module, sensor assembly, Signal Spacing conditioning module, data acquisition module, power module, output control module, read-out and touch screen module.The embedded main board module is the core of universal tower crane intelligent control monitor unit; This module adopts embedded microprocessor ARM 9 as MCU; Plate carries SDRAM and NAND Flash; Memory size can be adjusted according to user's request, and SDRAM is used for start-up routine and data cached, and NAND Flash is used to deposit embedded OS Linux, application program and tower machine operating data.System can expand the CF card of 1G in addition, and this card can be used to back up all data in the tower machine operational process, and the query function of these data is not provided on embedded system, but can read this card data through PC, and handles accordingly and analyze.The real-time clock of plate carrier band rechargeable battery can provide year, the moon, day, hour, minute, second temporal information, and this module can be given the status data confession of gathering in real time time tag.Pass through contact pin; On embedded main board, drawn the interface of ARM most function; Comprise: JTAG, I/O, RS232, RS485, USB, LCD, audio frequency, touch screen interface; Plug-in is all adopted in being connected of total interface and external equipment, and this not only makes system possess stronger function of seismic resistance, and is convenient to the flexible configuration of the system that realizes.In order to improve the stability of system, designed watchdog circuit on the embedded main board, the system that makes can automatically reset to normal condition after disturbing deadlock, program " race flies " or entering extremely to follow badly.Real-time running data at outage moment preservation tower machine has designed the power down protection circuit on embedded main board, the system that makes can be the structure optimization of tower machine at the generating process of reproduction accident afterwards, assert that accident liability provides foundation.
Sensor assembly confirms that according to the principal parameter that influences tower machine safety the principal parameter that influences tower machine safety has lifting power, hoisting moment, lifting altitude, degreeof turn, wind speed, tower machine inclination angle, flat arm and the carriage amplitude varying of tack arm tower machine, the tower arm elevation angle of swing arm tower machine.The collection of lifting information select for use the collection of pin type LOAD CELLS, tower boom slew select for use absolute optical encoder or multi-functional limiting device with potential device; Incremental encoder or multi-functional limiting device institute band potential device are selected in the collection of carriage amplitude varying and lifting altitude information for use; The photoelectric type air velocity transducer is selected in the collection of wind speed information for use, and absolute value angle type sensor is adopted at tower machine inclination angle.The sensor of arbitrary type all can adopt the analog signal of 0~5V or 4~20mA output, or adopts the digital signal of RS485 bus output, and the corresponding signal process method can be selected according to the input type of signal by system.This has increased the alerting ability of user on sensor is selected, and also is convenient to user's expanding monitoring object.If the signal of gathering is an analog signal, then this signal is passed through the Signal Spacing conditioning module, signal is carried out filtering, isolation, anti-interference process, be transported to the A/D module then, signal is gathered, and converted into corresponding physical quantity.According to the MODBUS agreement, be translated into the RS485 signal through communication protocol conversion device, be connected on the RS485 bus.If the signal of gathering then is directly connected on the RS485 bus for the digital signal of RS485 bus output.The signal of being gathered all sends to embedded main board through the RS485 bus at last and carries out data handing.According to default, the analog signal of being gathered is no more than 8 the tunnel, and under 0~8 tunnel situation, system architecture need not carried out any change, only needs sensor is connected on the respective channel to get final product, and this is convenient to the user and selects monitored object according to demand.Digital sensor for the output of RS485 bus can reach 256 the tunnel at most, is easy to the flexible extension of the system that realizes.
The number of embedded main board is adopted control module and is linked to each other with data acquisition module through the RS485 bus, and patrols survey through application program intelligent transducer to each passage in certain time interval, realizes the collection and the storage of tower machine working data.In order to eliminate the interference of some singular signal, adopt median filtering technology, it is handled.On the ARM platform, realize being kept in the data bank behind data acquisition, data analysis and the pretreatment.
The output control module of embedded main board, is controlled each actr then and is cut-off to PLC or relay through RS485 interface output switching value control signal, thus functions such as realization motion control;
Embedded main board drives on-the-spot display module through the TFT interface; Data are carried out can going up the working parameter that shows the tower machine in real time at ARM flat-bed LCD (touch-screen) after the analyzing and processing, automatically work-hours, periodical duty number of times, alarm condition, weight and the moment overload information etc. of storage column machine; The colorful display screen that ability is compatible 5.7 inches, 8.4 inches, 10.4 inches, the needs of suitable different user.
Embedded main board links to each other with touch-screen through touch screen interface, realizes the man-machine interaction between user and embedded main board, and system initialization, parameter modification, tower machine operation information are downloaded, and the inquiry of reporting to the police all can be accomplished through touch-screen.
COBBAIF on the embedded main board links to each other with loudspeaker, the voice signal of output hommization during warning, rather than ear-piercing buzzer.
USB interface on the embedded main board, but the conventional USB flash disk of direct connection are uploaded the basic specification of tower machine; Realize system initialization; Also can download the operating data and the historical data of tower machine, reproduce the work course of tower machine, for the structure optimization of tower machine, accident analysis provide foundation.
Power module adopts the linear stabilized power supply design plan; Through antisurge, power supply transformation, rectifying and wave-filtering, voltage stabilizing output four processes; With the 220V alternating current; Become the direct current (DC) of 3.3V, 5V, 12V, three kinds of form outputs of 24V, be each sensor, embedded main board, output control equipment, demonstration and touch-screen provide galvanic current; Power module provides necessary signal prompt and circuit working state prompting through charactron, LED lamp.
Comprehensive above-mentioned each module, the universal monitoring system of tower machine can be divided into information acquisition and control, information processing and show two parts, adopt information acquisition and controller respectively, and information shows and processing instrument is realized its function.In order to reduce the interference of electric power source pair of module embedded main board, power module is integrated in information acquisition and the control capsule.Collection and controller are installed on the side wall of tower machine operation chamber, and information shows and processing instrument is installed in the easiest observed place of driver.Communication between information acquisition and controller and information demonstration and the processing instrument is accomplished through a shielded multiconductor cable.System hardware structure is as shown in Figure 1.
According to the modular design principle, system software is divided into graded encryption module, the automatic update module of system, parameter module, system calibrating module, data acquisition and conditioning module, lifting characteristic monitoring module, warning enquiry module, work statistic module are set.
The alarming threshold value of tower office bond parameter is the guarantee of tower machine safe operation, and tower machine operating data is prediction tower machine service life, optimize tower machine structure, analyze accident causation, assert the foundation of accident liability.Existing tower machine monitor on the market; Mostly with the plaintext form with these data storage in data bank; Adopt general password authentication and access technique, these data are inquired about and revised, the hacker is easy to invade data bank; Make the safety of data bank can't be ensured fully that monitor also is difficult to really play the effect of tower machine " black box ".According to its demand for security; The present invention with tower is quick-witted in can control monitor unit data bank according to keywords section be divided into different security classifications; Divide rank to encrypt with symmetric encipherment algorithm to critical field; And, realize the related of user's rights of using and critical field level of security with elliptic curve encryption algorithm protected data key.Can guarantee that so a plurality of authorized users carry out other visit of classification to same encrypted fields.Only reach corresponding encrypted fields in other user's ability access encrypted data bank of level and the data bank; And can visit the encrypted fields below its rank; Thereby guarantee the confidentiality and integrity of critical data, make the quick-witted ability of tower control monitor unit really become tower machine " black box ".
Tower is quick-witted freely to be switched between work and management mode by control monitor unit in order to make; Be divided into mode of operation and management mode two states; The state of system default is a mode of operation; As long as device powers on, system bootstrap routine will start tower machine condition monitoring software automatically, and tower machine running state is monitored; Show the running state information of tower machine in real time through read-out, comprise specified hoisting moment, moment degree, lifting altitude, degreeof turn, wind speed, tower machine inclination angle, flat arm and the carriage amplitude varying of tack arm tower machine under the specified lifting power under actual lifting power, the current working, actual hoisting moment, the current working, the tower arm elevation angle of swing arm tower machine.When dangerous operating mode occurring, send alerting signal with voice, light, the three kinds of synchronous Xiang Taji drivers of form in ejection warning interface, and the output control signal corresponding, protection tower machine.Be specially: early warning when hoisting capacity reaches rated load weight 90%; The operation that warning and cut-out hoist and make progress when hoisting capacity reaches rated load weight 105%.Early warning when hoisting moment reaches rated moment 80%; Outside and the operation upwards that hoists of warning and cut-out luffing when hoisting moment reaches rated moment 105%., suspension hook can cut off the action upwards that hoists when leaving crane arm 2.5m.When luffing inwardly and outwards reaches capacity the position, cut off the operation of the inside and outside respective direction of dolly.When wind speed reaches 13m/s, can send early warning signal, when wind speed reaches 20m/s, can send alerting signal and cut off working power.Under mode of operation, system shows tower machine current working state and alarm message automatically, and except that system withdraws from menu can use, other menu can not carry out any operation.
Switching between management mode and the mode of operation is accomplished through the model selection button on the click system initial interface.Under management mode, system update, the inquiry of reporting to the police, parameter are provided with interface and Relational database visit employing level Four encryption mode.The site operation people can only browse, and common management person can download, analyze alarm message, and the Senior Administrator can revise the alarming threshold value of tower machine, and highest handler can carry out initialization again to system, makes it adapt to the tower machine of different model.The inquiry of reporting to the police only provides to be browsed and download function; Anyone can not make amendment to data wherein; Lifting power, hoisting moment field to transfiniting in the alert data storehouse have been carried out encryption; Have only the Senior Administrator just can browse, prevent that to greatest extent the responsive field in the data bank from being distorted, for optimizing tower machine structure, assert that accident liability provides failure-free foundation.
System initialization carries out through the USB interface that system provides.Before initialization; With screen size, tower machine model and scantling of structure, tower machine installation site, position, barrier, hoisting moment property list; Make the EXCELL file of particular file name; Through format conversion file provided by the invention, convert the XML file that embedded system is very easily operated into again.Again it is dumped in the USB flash disk, USB flash disk is inserted into the USB interface on information demonstration and the processing instrument, according to system suggestion carry out initialization operation by highest handler.After initialization was accomplished, the Senior Administrator was provided with button through clicking parameter, can carry out modify, with the needs of conform variation, working conditions change to construction parameter, alarming threshold value, the control threshold values of tower machine.This cover system does not need specialized procedure person to participate in, and only needs the user to make corresponding EXCELL form, can realize the initialization of system.Under the situation that no specialized procedure person participates in, can make same set of device be applicable to the monitoring of flat arm, swing arm, tack arm tower machine, be very easy to the user.
The tower machine belongs to the construction machinery and equipment of mobile operation, and along with period of service, environment for use change, certain drift can appear in sensor signal, and therefore regularly system being demarcated is the necessary means that guarantees its monitoring accuracy.Consider that the tower machine is a Linear Elastic Structure, sensor is a linear transducer, therefore demarcates and adopts linear equation y=kx+b, and wherein x is the sensor sample value, and k, b are calibration coefficient, and y is a real physical.Calibration coefficient k, b adopt two-point method to confirm.That is: the two point (x that will gather 0, y 0) and (x 1, y 1) the substitution calibration equation, obtain set of equations about k, b, through the solving equation group, draw the value of k, b.Under the operational mode of system, the relation between sampled value x and the real physical y is:
y=[(y 1-y 0)/(x 1-x 0)](x-x 0)+y 0
System calibrating under management mode, provides the system calibrating menu for ease.Common management person only need click this menu, and system promptly can jump out corresponding calibration interface automatically, and is as shown in Figure 3.2 groups of standard values of input in the corresponding text frame can automatically show the observed reading of sensor in adjacent text box, press acknowledge button after, system can calculate the value of calibration coefficient k, b automatically.Through the periodic calibrating of system, can eliminate that temperature is floated, creep is to the influence of sensor and other components and parts, significantly improves the monitoring accuracy of system.
The hoisting moment monitoring is an important contents in the tower machine condition monitoring, through the real-time moment M (L) and the rated moment M of contrast tower machine e(L), thus the tower machine is carried out corresponding control.The real-time moment M of tower machine (L)=Q (L) * L, wherein Q (L) is actual hoisting capacity, L is a carriage amplitude varying.Specified hoisting moment M e(L)=Q e(L) * L, wherein Q e(L) be rated load weight.Rated load weight is a form that just designs at the beginning of the tower machine designs; Stored in the table is the rated load weight of certain specific location; Be discretization numerical value; And the displacement that monitors is a continuous changing value, therefore just need a corresponding lifting power allowable value be arranged in any position.According to the mechanical characteristic of tower machine, in system, designed the segmentation cubic spline functions, this function can be confirmed the specified lifting power of any arbitrarily according to the specified lifting power allowable value on each design point.
When hoisting capacity, hoisting moment break bounds, system will send alerting signal or control motor signal.Account for biggest lifting capacity Q according to current hoisting capacity Q MaxPercentum, to high, medium and low three speed thresholds change speed motor control, thereby realize according to lifting weight volitional check lifting velocity.Account for current rated moment M according to current hoisting moment M ePercentum, respectively the luffing motor of high and low two speed thresholds of tower machine is controlled, thereby is realized according to hoisting moment volitional check luffing speed.Its control flow chart is as shown in Figure 4.
In burst accident; The power supply of tower machine can cut off suddenly usually; And this time the tower machine strained condition most important to assert tower machine accident liability, if do not take measures to preserve the tower tester in power-down state operating data of moment, phenomenon just probably appears shifting responsibility onto others, disputing over trifles in responsible department.For addressing this problem, tower quick-witted can Design of Monitoring and Control System power-down protection, preserve the preceding 120 seconds operating data of tower machine sudden power.In these 120 seconds, data of per 0.1 second record of tower machine adopt the formation mode; Be stored in the 6*1200 two-dimensional array; The every row of array has 1200 elements, first row element storage be nearest time (year-moon-Ri-time-minute-second), what second row element was stored is the hoisting capacity of nearest 120 seconds tower machines; What the third line element was stored is the hoisting moment of nearest 120 seconds tower machines; What the fourth line element was stored is the luffing amplitude of nearest 120 seconds tower machines, and what the fifth line element was stored is the lifting altitude of nearest 120 seconds tower machines, and what the 6th row element was stored is the ambient wind velocity of nearest 120 seconds tower machines.Initial value zero setting, one group of data of every collection are picked out the tail element in the array, move behind the fwd element, newly advance first row that element places array, and what guarantee all the time to store in the array is the operating data of nearest 120 seconds tower machines.For improving the real-time of system response, prolong the service life of non-volatile memory chip FLASH, this array is buffered among the volatile memory SDRAM in program operation process, when the unexpected power down of system, writes in FLASH.
In order to realize this function, system has opened the power down monitoring thread of external interrupt thread and application program specially.The power-fail interrupt monitoring thread of application program is set to high priority, so that during power-fail interrupt, system carries out monitoring power-fail interrupt thread at once.When system got electric normal operation, external interrupt thread and power-fail interrupt monitoring thread all were suspended states.When the power down supervisory circuit detects unexpected power down, then produce and interrupt through the external interrupt pin, after the request of ARM microprocessor responds external interrupt, wake the processing threads of external interrupt up, it is notify status that synchronous event is set.After the power-fail interrupt monitoring thread received synchronous event, the data that system in time will be buffered among the SDRAM were write in FLASH, permanent storage.
The invention has the advantages that: system initialization is carried out automatically through the USB flash disk that has towering machine information in (1), makes it be applicable to the on-site supervision of flat arm, swing arm, tack arm tower machine; And on colorful display screen, show the working parameter of tower machine, the work-hours of storage column machine, periodical duty number of times, alarm condition, weight and moment overload information automatically in real time with the picture and text form; (2) the hoisting moment curve of automatic match tower machine is applicable to the different tower machines under any multiplying power, sound and light alarm when dangerous operating mode occurring, and can connect with PLC or relay through the RS485 communication interface, cut off corresponding control power supply; (3) because of the burst accident outage, system can write down the instantaneous work state information of tower tester in power-down state, for appearing historical events in one's mind, confirms accident liability, and the firsthand information is provided.
Description of drawings
Fig. 1 is a tower machine high-level schematic functional block diagram.
Fig. 2 is the quick-witted ability of a tower control monitor unit structural representation.
Fig. 3 is the transducer calibration surface chart.
Fig. 4 is real-time hoisting capacity, hoisting moment monitoring diagram of circuit.
The specific embodiment
This intelligence monitoring and controlling device control capsule and read-out are installed in the tower machine operator's compartment control cabin; Height sensor is installed on the lifting mechanism; The amplitude sensor is installed on the luffing mechanism, and weight sensor is installed in the tower machine dynamometry annulate shaft, and each sensor is connected with control capsule through cable.After control monitor unit and circuit thereof install, must carry out the demarcation of parameter, just can correctly show.Operating display enters into management mode, the control tower machine counterweight of known weight of slinging, wait suspension hook stable after, the actual lift heavy of tower machine is input in the read-out; Then, counterweight is put down, make the empty hook of suspension hook, more empty hook weight 0 is input in another data of read-out, thereby realizes demarcation tower machine weight.Equally, supplemental characteristics such as the height of change tower machine, luffing amplitude, degreeof turn can be realized the demarcation to other data.

Claims (5)

1. tower is quick-witted can monitored control system; Comprise control capsule (1), read-out (2), height sensor (3), amplitude sensor (4), weight sensor (5); It is characterized in that: control capsule and read-out are installed in the tower machine operator's compartment control cabin, and height sensor is installed on the lifting mechanism, and the amplitude sensor is installed on the luffing mechanism; Weight sensor is installed in the tower machine dynamometry annulate shaft, and each sensor is connected with control capsule (1) through cable; This system adopts modular design, comprising: embedded main board module, sensor assembly, Signal Spacing conditioning module, data acquisition module, power module, output control module, read-out and touch screen module.
2. the quick-witted ability of tower according to claim 1 monitored control system is characterized in that embedded main board adopts embedded microprocessor ARM 9 as MCU; Mainboard is provided with SDRAM and NAND Flash; Mainboard is provided with slot, and this slot is placed the CF card of expansion, is provided with JTAG, I/O, RS232, RS485, USB, LCD, audio frequency, touch screen interface on the mainboard; Plug-in is all adopted in being connected of total interface and external equipment, and mainboard is provided with USB interface.
3. the quick-witted ability of tower according to claim 1 monitored control system; It is characterized in that system software is divided into graded encryption module, the automatic update module of system, parameter module, system calibrating module, data acquisition and conditioning module, lifting characteristic monitoring module, warning enquiry module, work statistic module are set.
4. the quick-witted ability of tower according to claim 1 monitored control system is characterized in that, demarcates and adopts linear equation y= Kx+ b, wherein xBe the sensor sample value, K, bBe calibration coefficient, yBe real physical; Calibration coefficient K, bAdopt two-point method to confirm; 2 points that is: will gather ( x 0, y 0) and ( x 1, y 1) the substitution calibration equation, obtain about K, bSet of equations, through the solving equation group, draw K, bValue.
5. tower according to claim 1 is quick-witted can monitored control system, it is characterized in that, tower quick-witted can Design of Monitoring and Control System power-down protection, preserve the preceding 120 seconds operating data of tower machine sudden power; In these 120 seconds, data of per 0.1 second record of tower machine adopt the formation mode; Be stored in the 6*1200 two-dimensional array; The every row of array has 1200 elements, first row element storage be nearest time (year-moon-Ri-time-minute-second), what second row element was stored is the hoisting capacity of nearest 120 seconds tower machines; What the third line element was stored is the hoisting moment of nearest 120 seconds tower machines; What the fourth line element was stored is the luffing amplitude of nearest 120 seconds tower machines, and what the fifth line element was stored is the lifting altitude of nearest 120 seconds tower machines, and what the 6th row element was stored is the ambient wind velocity of nearest 120 seconds tower machines; Initial value zero setting, one group of data of every collection are picked out the tail element in the array, move behind the fwd element, newly advance first row that element places array, and what guarantee all the time to store in the array is the operating data of nearest 120 seconds tower machines.
CN 201110372304 2011-11-21 2011-11-21 Intelligent tower crane monitoring system Expired - Fee Related CN102398868B (en)

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