CN108510831A - Automate bridge crane remote operation simulator - Google Patents

Automate bridge crane remote operation simulator Download PDF

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Publication number
CN108510831A
CN108510831A CN201810562275.2A CN201810562275A CN108510831A CN 108510831 A CN108510831 A CN 108510831A CN 201810562275 A CN201810562275 A CN 201810562275A CN 108510831 A CN108510831 A CN 108510831A
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CN
China
Prior art keywords
bridge crane
simulator
automation
remote operation
crane
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Pending
Application number
CN201810562275.2A
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Chinese (zh)
Inventor
赵斌
周颖达
闻佳华
马矜
黄志伟
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shanghai Zhenghua Heavy Industries Co Ltd
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Shanghai Zhenghua Heavy Industries Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by Shanghai Zhenghua Heavy Industries Co Ltd filed Critical Shanghai Zhenghua Heavy Industries Co Ltd
Priority to CN201810562275.2A priority Critical patent/CN108510831A/en
Publication of CN108510831A publication Critical patent/CN108510831A/en
Pending legal-status Critical Current

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    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09BEDUCATIONAL OR DEMONSTRATION APPLIANCES; APPLIANCES FOR TEACHING, OR COMMUNICATING WITH, THE BLIND, DEAF OR MUTE; MODELS; PLANETARIA; GLOBES; MAPS; DIAGRAMS
    • G09B9/00Simulators for teaching or training purposes

Abstract

The present invention discloses a kind of automation bridge crane remote operation simulator, including hardware system and software systems, hardware system include:Remote console, lecturer's platform and server cabinet;Software systems include:Simulator software, gantry crane management system, automatic control system, the automatically controlled PLC of bridge crane single machine, equipment monitoring system and system for managing video.The automation bridge crane remote operation simulator greatly improves the operating efficiency that driver hangs in true automation bridge, and then helps to improve harbour entirety professional skill.

Description

Automate bridge crane remote operation simulator
Technical field
The present invention relates to bridge crane remote control technologies, more specifically refer to a kind of automation bridge crane remote operation simulator.
Background technology
In recent years, global automatic dock construction demand emerges in large numbers like the mushrooms after rain, unlike traditional bridge crane, automatically The mode of operation for changing bridge crane switchs to remotely from local, some harbours have even completely abolished local drivers' cab.It can be seen that base Traditional bridge crane simulator designed by local drivers' cab cannot be satisfied the training requirement of automation bridge crane operator, and research and development are suitable Remote operation simulator for automating gantry crane is imperative.
In order to allow operator to obtain operating experience true to nature, automation bridge crane remote operation simulator is not only adopted on hardware Identical remote console is designed with prototype, will also be used and the identical automated software frame of prototype on software Structure and man-machine interface.Therefore, by systematically training practice, operator can not only be familiar with remote-operated basic skills, A whole set of automated job flow and abnormality processing flow more can be skillfully grasped, to efficiently promote the synthesis energy of trained operator Power, but also training becomes more meaningful and value.
It is functional outer in addition to having the institute of traditional gantry crane simulator, it automates bridge crane remote operation simulator and also needs to simulate A series of auxiliary systems necessary to all automated jobs, such as electronic anti-swinging, the anti-torsion of electronics, semi-automatic, truck guiding, ship type Scanning, suspender detection, object detection system etc..
In addition, it is different from actual production environment institute, there was only virtual vessel at anchor, packaging in simulator dummy activity scene Case, gantry crane and straddle carrier, therefore how by a whole set of true production system of virtual scene information and harbour and control system It is combined, becomes the key problem and difficult point in automation bridge crane remote operation simulator technology scheme.
Invention content
The object of the present invention is to provide a kind of automation bridge crane remote operation simulators, to automate bridge crane bottom PLC journeys Based on sequence, single plane automation control system, gantry crane management system, equipment monitoring system, screen management system, in conjunction with simulation Operating environment and implement fully consider the practicability and high efficiency of training.The automation bridge crane remote operation simulator pole The earth improves the operating efficiency that driver hangs in true automation bridge, and then helps to improve harbour entirety professional skill.
To achieve the goals above, the present invention uses following technical scheme:
A kind of automation bridge crane remote operation simulator, including hardware system and software systems, the hardware system include: Remote console, lecturer's platform and server cabinet;The software systems include:Simulator software, gantry crane management system, automation Control system, the automatically controlled PLC of bridge crane single machine, equipment monitoring system and system for managing video, wherein:
The remote console includes multiple displays, multiple computer works, multiple I/O modules, PLC controller, touches It touches screen, multiple operation handles, tightly stop button, ACCS all-in-one machines, Profinet interchangers;
Lecturer's platform includes multiple displays;
Server cabinet includes multiple Ethernet switches, multiple images processing server, database and OPC common services Device, simulator work station, multiple screen encoders and KVM switcher;
The simulator software simulates the virtual training field being made of bridge crane, ship, container, straddle carrier, quay surface Scape;All devices information in virtual training scene is handed down to the automatically controlled PLC of bridge crane single machine;According in virtual analog scene STOWAGE PLAN information simulation TOS generate virtual TOS job tasks and be handed down to gantry crane management system;It simulates virtual on all bridge cranes Camera video signal simultaneously exports after recompiling to system for managing video;
The job task received is resolved into automated job and instruct and be handed down to automation by gantry crane management system to be controlled System processed;
The automated job received instruction is converted to device action and instructs and be handed down to bridge by the automatic control system The automatically controlled PLC of single machine is hung, while the execution state that automated job instructs is returned into gantry crane and manages system;
The automatically controlled PLC of bridge crane single machine instructs the device action received or the manual control signal of remote console is defeated Go out to simulator software, to control the specific action of virtual bridge crane, and execution state is returned into automatic control system;By bridge All status informations and fault message for hanging equipment are exported to equipment monitoring system;
The equipment monitoring system exports the status information of equipment received and fault message to remote console;
The system for managing video CCTV exports the virtual camera vision signal received to remote console.
Preferred embodiment according to the present invention, multiple displays of remote console are 6, multiple computer works are 2 A, multiple operation handles are 2;Multiple displays of lecturer's platform are 3;Multiple Ethernet switches of server cabinet are 2 A, multiple images processing server is 3, multiple screen encoders are 5.
In the remote console, connected by HDMI wire between computer work and display;PLC controller and I/O It is connected by hardware connecting line between equipment;Lead between Profinet interchangers and PLC controller, touch screen and ACCS all-in-one machines Cross the connection of Profinet lines.
In the server cabinet, Ethernet switch is shared with video encoder, image server, database and OPC It is realized and is connected by ethernet line between server, simulation work station and KVM switcher;Ethernet switch also with remotely Work station, Profinet interchangers in operation console and between ACCS all-in-one machines pass through Ethernet realize connection;Server cabinet In image server and video encoder between, the KVM switcher in server cabinet and between the display in lecturer's platform, It is realized and is connected by HDMI wire between display in simulator work station in server cabinet and lecturer's platform.
The gantry crane management system docks the gantry crane using the software module in real system by oracle database Data between management system and true TOS interact.
The simulator software has function and interface virtual TOS identical with true TOS, by the way that TOS information to be written TOS job tasks are managed system by oracle database to be handed down to gantry crane.
Data interaction between the simulator software and the automatically controlled PLC of bridge crane single machine realizes the two using OPC communication protocols The docking of module.
Opc server is established in the automatically controlled sides PLC of bridge crane single machine, and simulator software end is as OPC client, the simulation Device software carries out data communication interaction with the automatically controlled PLC of bridge crane single machine.
The simulator software exports virtual camera vision signal to video encoder, and video is re-encoded as by it Vision signal is exported to screen by ICP/IP protocol and manages system by the H.264 coding form that management software is supported.
The data interaction of gantry crane management system and the automatic control system using OPC communication protocols realize this two The docking of a module.
Data interaction between the automatic control system and the automatically controlled PLC of bridge crane single machine is real using Profinet agreements The docking of the two existing modules.
Data interaction between the automatically controlled PLC of bridge crane single machine and the equipment monitoring system is realized using OPC communication protocols The docking of the two modules.
Novel automatic bridge crane remote operation simulator using the present invention, can under almost operation training true to nature, It not only allows operator to be familiar with remote-operated basic skills, more can skillfully grasp a whole set of automated job flow and abnormality processing Flow.
Description of the drawings
Upon reading the detailed description of non-limiting embodiments with reference to the following drawings, other feature of the invention, Objects and advantages will become more apparent upon.
Fig. 1 is the hardware topology figure of automation bridge crane remote operation simulator according to the present invention;
Fig. 2 is the architecture diagram of automation bridge crane remote operation simulator according to the present invention;
Fig. 3 is the screen display of the automation bridge crane remote operation simulator of the present invention.
Specific implementation mode
Technical scheme of the present invention is specifically described below in conjunction with Figure of description.
Describe the detailed features and advantage of the present invention in detail in a specific embodiment below, content is enough to make any Skilled in the art realises that the technology contents of the present invention and implement according to this, and specification disclosed by this specification, weigh Profit requires and attached drawing, skilled person readily understands that the relevant purpose of the present invention and advantage.
Traditional bridge crane simulator is based on local drivers' cab and designs, and automation bridge crane remote operation simulator of the invention is not It is same as conventional simulator, the technical issues of which solve following three aspects:First, can simulate necessary to all automated jobs A series of auxiliary systems, such as electronic anti-swinging, the anti-torsion of electronics, semi-automatic, truck guiding, the scanning of ship type, suspender detection, target detection System etc.;Second is that realizing all dummy activity information such as gantry crane, STOWAGE PLAN, straddle carrier in virtual scene and harbour are true Production system and control system docking;Third, realizing camera video image and the true screen management in virtual scene System docking.
Automation bridge crane remote operation simulator according to the present invention includes hardware system and software systems.
Hardware system
Fig. 1 shows the hardware topology figure of automation bridge crane remote operation simulator according to the present invention.
As shown in Figure 1, the hardware system of automation bridge crane remote control simulator includes mainly:Remote console, lecturer Platform and these three parts of server cabinet composition.Wherein:
Remote console includes 6 displays, 2 computer works, 1 PLC controller, several I/O modules, 1 behaviour Effect touch screen, 2 operation handle (not shown)s, 1 it is tight stop button (not shown), 1 ACCS all-in-one machine, 1 Profinet interchangers.
In remote console, connected by HDMI wire between computer work and display;PLC controller and I/O equipment Between connected by hardware connecting line;Pass through between Profinet interchangers and PLC controller, touch screen and ACCS all-in-one machines Profinet lines connect.
In order to obtain operating experience true to nature, remote console use and the duplicate appearance design of true operation platform and Component is arranged, is integrated with handle and push button function, video display function, equipment state needed for operator's operation equipment and is shown Function, malfunction coefficient function etc..
Lecturer's platform is equipped with 3 displays.The major function of lecturer's platform includes:Configure Training scene, abnormal failure triggering, The adjusting of scene climatic environment, scene illumination intensity adjustment, operator's points-scoring system etc..
Server cabinet includes:2 Ethernet switches, 3 image processing servers, 1 database and OPC share clothes Business device, 1 simulator work station, 5 screen encoders and 1 KVM switcher.
In server cabinet, Ethernet switch and video encoder, image server, database and OPC common services It is realized and is connected by ethernet line between device, simulation work station and KVM switcher.In addition, the Ethernet in server cabinet Interchanger, which is realized also between work station, Profinet interchangers and the ACCS all-in-one machines in remote console by Ethernet, to be connected It connects.Between image server and video encoder in server cabinet, in the KVM switcher in server cabinet and lecturer's platform Display between, realized by HDMI wire between the display in the simulator work station in server cabinet and lecturer's platform Connection.
Image server in server cabinet is responsible for handling the video image of virtual camera and be exported to Video coding Device;Database/opc server is responsible for the data interaction for handling database and OPC communications.
Software systems
Fig. 2 shows the architecture diagrams of automation bridge crane remote operation simulator according to the present invention.
As shown in Fig. 2, the software systems of automation bridge crane remote control simulator include following six module:Simulator is soft Part, gantry crane management system QCMS (Quay Crane Management System), automatic control system ACCS (Automatic Crane Control System), the automatically controlled PLC of bridge crane single machine, equipment monitoring system CMS (Crane Monitor System) and system for managing video CCTV.
The major function of above-mentioned modules is as follows:
Simulator software module builds the virtual training being made of bridge crane, ship, container, straddle carrier, quay surface etc. Scene, and all devices information in virtual analog scene is interacted with the automatically controlled PLC of bridge crane single machine;According to virtual analog field STOWAGE PLAN information simulation TOS in scape generates job task and is handed down to gantry crane management system;Simulate virtually taking the photograph on all bridge cranes Camera vision signal, output is to system for managing video after recompiling.
Gantry crane manages system QCMS modules and the job task received is resolved into automated job instruction, and is handed down to automatic Networked control systems ACCS.
Automatic control system ACCS modules are instruction morphing at more specifically device action by the automated job received The automatically controlled PLC of bridge crane single machine is instructed and be handed down to, while the execution state that automated job instructs is returned into gantry crane and manages system QCMS。
The automatically controlled PLC module of bridge crane single machine instructs the device action received or the manual control signal of operation console is exported to mould Execution state is returned to automatic control system ACCS moulds by quasi- device software module to control the specific action of virtual bridge crane Block;All status informations and fault message of bridge crane equipment are exported and give equipment monitoring system CMS modules.
Equipment monitoring system CMS exports the status information of equipment received and fault message to remote console.
System for managing video CCTV exports the virtual camera vision signal received to remote console.
In the automation bridge crane remote control simulator scheme of the present invention, there is complexity between each software module Data interaction, interactive data include virtual bridge hang control signal/status feedback information, automated job instruction, instructed At state, video flowing etc..By limitations such as each software module institute supported protocol is different, the hardware interface differences of place equipment Property, how to solve the problems, such as that the data interaction of these intermodules also becomes the difficult point during technical solution of the present invention is implemented.The present invention adopts Simulator software and gantry crane management system, simulator software are realized with following technological means and bridge crane single machine is automatically controlled, simulator Software and system for managing video, gantry crane management system and automatic control system, automatic control system and bridge crane single machine it is automatically controlled, The automatically controlled data interaction between equipment monitoring system of bridge crane single machine.
The data interaction of simulator software and gantry crane management system
To restore the automated job flow of true bridge crane, gantry crane management system QCMS has used the software in real system Module, and its data interaction between true TOS is docked by oracle database.Therefore, simulator software is also thus The virtual TOS with said function and same-interface is developed, by the way that Oracle is written in automated job task (TOS information) Database manages system to be handed down to gantry crane.
Simulator software and the automatically controlled data interaction of bridge crane single machine
Control signal/status feedback information of virtual bridge crane needs between simulator software and the automatically controlled PLC of bridge crane single machine Frequent data interaction is carried out, to realize that this target, scheme have set up bridge using OPC communication protocols in two intermodules, PLC establishes side OPC Server, and simulator software end carries out data communication interaction as OPC Client clients, both sides.
The data interaction of simulator software and system for managing video
The video flowing that simulator software generates need to unidirectionally be handed down to system for managing video and finally show to remote console, For this purpose, Scheme Choice first exports video flowing to video encoder, H.264 video management software support is re-encoded as by it Coding form, then video flowing final output to screen is managed by system by ICP/IP protocol.
Gantry crane manages the data interaction of system and automatic control system
The TOS job tasks received need to be resolved into automated job instruction by gantry crane management system QCMS, and is handed down to certainly Dynamic networked control systems ACCS, and ACCS need to timely feedback instruction completion status to QCMS.For this purpose, technical scheme of the present invention is sharp The two modules are docked with OPC communication protocols, successfully realize the data interaction of automated job instruction.
Automatic control system and the automatically controlled data interaction of bridge crane single machine
Automatic control system ACCS need to refer at more specifically device action by the automated job received is instruction morphing The automatically controlled PLC of bridge crane single machine is handed down to after order, and PLC then needs the execution state of action command returning to ACCS in time, to realize The data interaction of this layer, technical scheme of the present invention select Profinet agreements.
The automatically controlled data interaction with equipment monitoring system of bridge crane single machine
The automatically controlled PLC of bridge crane single machine need to unidirectionally export all status informations and fault message of bridge crane equipment to monitoring of tools System CMS, and it is finally shown in remote console, with reference to the application case of conventional project, Scheme Choice OPC Server conducts The medium of data interaction.
Fig. 3 is the simulator material object screen display using present invention automation bridge crane remote operation simulator.
The present invention can reach following technique effect:
In terms of economy, automation bridge crane remote operation simulator according to the present invention can allow operator skillfully to grasp Remote-operated basic skills and automated job flow to effectively promote unit operation efficiency, and then promote entire code The professional skill of head creates the economic benefit of bigger for harbour;The simulator can be done sth. in advance before true bridge crane is delivered for use Operator's training is carried out, directly equipment investment can be produced when bridge crane is delivered, improve bridge crane utilization rate of equipment and installations.
In terms of safety, automation bridge crane remote operation simulator according to the present invention can train operator for urgent The Ability of emergency management of emergency case and the operational capacity under severe weather conditions are made so as to effectively improve true bridge crane The safety coefficient of industry reduces the frequency of maintenance and intensity of maintenance personal.
Finally it is pointed out that although the present invention is described with reference to current specific embodiment, this technology is led Those of ordinary skill in domain it should be appreciated that more than embodiment be intended merely to illustrate the present invention, and be not used as to this The restriction of invention can also make various equivalent change or replacement without departing from the inventive concept of the premise, therefore, as long as The variation, modification of above-described embodiment will all be fallen in claims of the present invention range in the spirit of the present invention It is interior.

Claims (12)

1. a kind of automation bridge crane remote operation simulator, it is characterised in that:The simulator includes hardware system and software system System, the hardware system include:Remote console, lecturer's platform and server cabinet;The software systems include:Simulator is soft Part, gantry crane management system, automatic control system, the automatically controlled PLC of bridge crane single machine, equipment monitoring system and system for managing video, In:
The remote console include multiple displays, multiple computer works, multiple I/O modules, PLC controller, touch screen, Multiple operation handles tightly stop button, ACCS all-in-one machines, Profinet interchangers;
Lecturer's platform includes multiple displays;
Server cabinet include multiple Ethernet switches, multiple images processing server, database and OPC common servers, Simulator work station, multiple screen encoders and KVM switcher;
The simulator software simulates the virtual training scene being made of bridge crane, ship, container, straddle carrier, quay surface;It will All devices information in virtual training scene is handed down to the automatically controlled PLC of bridge crane single machine;According to the ship in virtual analog scene Figure information simulation TOS generates virtual TOS job tasks and is handed down to gantry crane management system;Simulate the virtual camera shooting on all bridge cranes Machine vision signal simultaneously exports after recompiling to system for managing video;
The job task received is resolved into automated job and instructs and be handed down to automation control system by gantry crane management system System;
The automated job received instruction is converted to device action and instructs and be handed down to bridge crane list by the automatic control system Electrical Control PLC, while the execution state that automated job instructs is returned into gantry crane and manages system;
The automatically controlled PLC of bridge crane single machine by the device action received instruct or remote console manual control signal export to Execution state to control the specific action of virtual bridge crane, and is returned to automatic control system by simulator software;Bridge crane is set Standby all status informations and fault message are exported to equipment monitoring system;
The equipment monitoring system exports the status information of equipment received and fault message to remote console;
The system for managing video exports the virtual camera vision signal received to remote console.
2. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The multiple of remote console show Show that device is 6, multiple computer works are 2, multiple operation handles are 2;Multiple displays of lecturer's platform are 3;Service Multiple Ethernet switches of device cabinet are 2, multiple images processing server is 3, multiple screen encoders are 5.
3. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:In the remote console, It is connected by HDMI wire between computer work and display;Connected by hardware connecting line between PLC controller and I/O equipment It connects;It is connected by Profinet lines between Profinet interchangers and PLC controller, touch screen and ACCS all-in-one machines.
4. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:In the server cabinet, Ethernet switch and video encoder, image server, database and OPC common servers, simulation work station and KVM It is realized and is connected by ethernet line between switch;Ethernet switch also with work station, the Profinet in remote console It is realized and is connected by Ethernet between interchanger and ACCS all-in-one machines;Image server in server cabinet and video encoder Between, the KVM switcher in server cabinet and the simulator work station between the display in lecturer's platform, in server cabinet It is realized and is connected by HDMI wire between the display in lecturer's platform.
5. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The gantry crane management system makes With the software module in real system, the data between the gantry crane management system and true TOS are docked by oracle database It interacts.
6. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The simulator software has Function and interface virtual TOS identical with true TOS, by by TOS information be written oracle database by TOS job tasks come It is handed down to gantry crane management system.
7. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The simulator software and bridge Hang the docking that the two modules are realized in the data interaction between the automatically controlled PLC of single machine using OPC communication protocols.
8. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The bridge crane single machine is automatically controlled PLC establishes side opc server, and simulator software end is as OPC client, the simulator software and the automatically controlled PLC of bridge crane single machine Carry out data communication interaction.Interaction content is given for the order of gantry crane and its subsystem and status feedback information.
9. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The simulator software will be empty Quasi- camera video signal is exported to video encoder, and the H.264 coding shape of video management software support is re-encoded as by it Vision signal is exported to screen by ICP/IP protocol and manages system by formula.
10. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The gantry crane manages system Docking for the two modules, interactive data are realized using OPC communication protocols with the data interaction of the automatic control system The feedback information of the execution state of automated job instruction and automated job instruction including decomposition.
11. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The automation control system The data interaction united with automatically controlled of the bridge crane single machine being docked using the two modules of Profinet protocol realizations, interactive number According to the feedback information of the instruction of gantry crane mechanism action and action execution state including decomposition.
12. automation bridge crane remote operation simulator as described in claim 1, it is characterised in that:The bridge crane single machine is automatically controlled Data interaction between PLC and the equipment monitoring system realizes docking for the two modules, interactive number using OPC communication protocols According to real time status information and fault message including gantry crane.
CN201810562275.2A 2018-06-04 2018-06-04 Automate bridge crane remote operation simulator Pending CN108510831A (en)

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