CN109704201B - Intelligent operation control system of bridge crane - Google Patents
Intelligent operation control system of bridge crane Download PDFInfo
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Abstract
The invention provides an intelligent operation control system of a bridge crane, which mainly comprises a position correction module, an anti-swing unit module, a data processing module and a PLC (programmable logic controller), wherein the position correction module is used for determining coordinates of an object and adjusting the lifting angle of the object, and the position correction comprises a coordinate measuring unit, a distance sensing sensor, an offset compensation sensor, an angle sensor and a coordinate guiding unit; the anti-swing module comprises an acceleration sensor, a height sensor, a swing prediction unit, a tracking control unit and a frequency sensor; the data processing module is used for receiving the position correction and anti-swing data, the data processing unit sends the processed data to the PLC, the data processing module comprises a receiving unit, a signal processing unit and a data quantitative analysis unit, and through cooperation of the modules, the swing amplitude of a moving object is reduced, and intelligent operation is achieved.
Description
Technical Field
The invention belongs to the technical field of cranes, and particularly relates to an intelligent operation control system of a bridge crane.
Background
The lifting difficulty is increased due to large-scale industrial development in China, the lifting scheme design serving as lifting safety guarantee is higher and higher in rationality, accuracy, safety and reliability, however, the conventional crane lifting scheme formulation basically adopts manual experience, wherein the core content lifting path planning of the scheme has the problem of lacking theoretical basis, the lifting safety is seriously influenced, so that the lifting path planning is needed, and the lifting scheme is formulated, so that a favorable reference is provided for reasonably and efficiently utilizing crane resources.
However, the formulation of the hoisting scheme is very complex, the effectiveness and safety of the hoisting scheme cannot be ensured, and the hoisting scheme is basically completed by virtue of manual experience in the formulation process. The hoisting scheme aiming at large-scale and huge equipment and complex operation environment is formulated only by a traditional method, so that the requirements of high precision, high efficiency and high safety of modern hoisting cannot be met, particularly the problem of hoisting path planning is solved, accurate, safe and effective paths cannot be obtained by manual experience, and huge potential safety hazards exist.
When the crane is used for carrying materials, the carrying object is firstly pulled outwards and obliquely, the carrying object is moved to the middle and lower parts of the crane, and the angle formed between the traction wire and the carrying object is easily overlarge, so that the slightly disordered groove of the steel wire rope is caused, the rope guider is dislocated or damaged, and the serious phenomenon is that the steel wire rope is broken. The movements of the crane cart, trolley and lifting mechanism are typically independently controlled by respective operating instructions. When the handled material reaches the target location, the load may undesirably sway due to the acceleration and deceleration of the cart and trolley. When the load swings, the unloading operation cannot be performed. In this case, only a skilled operator may control the operation of the cart to eliminate the sway. However, this requires a very skilled operator skill and a high degree of concentration. Eliminating the sway of the load and finely adjusting the load to the target position requires a long operation time, which takes about one third of the time required for the entire handling work. In addition, the rapid running of the crane causes a sway of the load too great. Excessive load sway poses a threat to the personal safety of field operators. The load sway also increases the likelihood of damage to the load and surrounding cargo, which reduces the efficiency of work on the crane and also affects safe operation.
Disclosure of Invention
Aiming at the problems, the invention provides an intelligent operation control system of a bridge crane.
The technical scheme of the invention is that the intelligent operation control system of the bridge crane mainly comprises a position correction module, an anti-swing module, a data processing module and a PLC controller;
the position correction comprises a coordinate measuring unit, a distance sensing sensor, an offset compensation sensor, an angle sensor and a coordinate guiding unit; the coordinate measuring unit is used for establishing coordinates to carry out position marking on the operation of the object; the distance sensing sensor is used for measuring the set distance of the distance coordinates of the moving position of the object; the offset compensation unit is used for offset compensation of the actual coordinates; the angle sensor is used for measuring the inclined dragging angle of the object on the crane coordinates; the coordinate guiding unit comprises a pulse coding signal and an activity type, and is used for transmitting the pulse coding signal to an object to determine moving process information and carrying out real-time adjustment;
the anti-swing module comprises an acceleration sensor, a height sensor, a swing prediction unit, a tracking control unit and a frequency sensor; the acceleration sensor is used for recording the acceleration of the crane accelerated to the maximum speed; the height sensor records the rising height of the object; the swing prediction unit is used for recording the actual and predicted swing paths of the object; the tracking speed control unit is used for adjusting the speed of the path recorded by the swing prediction unit; the frequency sensor is used for recording the frequency when the object swings;
the data processing module comprises a receiving unit, a signal processing unit and a data quantization analysis unit, wherein the receiving unit is used for receiving the position correction and anti-swing data and integrating and transmitting the received data to the signal processing unit; the signal processing unit is used for classifying the integrated data; the data quantitative analysis unit analyzes and evaluates the extracted data and sends the processed data to the PLC; the PLC is used for editing data of the cart frequency converter, the trolley frequency converter and the lifting frequency converter.
Further, the coordinate guiding unit comprises a force sensor, wherein the force sensor is used for determining the recorded traction force of each coordinate, and the traction force of each coordinate is fed back and adjusted in real time through the data feedback unit.
Further, the swing-setting module comprises an amplitude modulation executing unit, wherein the amplitude modulation executing unit is used for calculating mechanical transmission gap data, transmitting ultrasonic pulse information and comparing a swing time interval with a preset time interval in the data.
Further, the control system comprises an early warning module, the early warning module is used for warning and alarming surrounding areas of the crane, the early warning module comprises an area information acquisition unit, an infrared sensor and a setting unit, the area information acquisition unit is used for carrying out rapid scanning analysis modeling on information of a using site and transmitting the analyzed information to the PLC, and the infrared sensor is used for carrying out scanning positioning processing on the using site.
Further, the frequency sensor is arranged on the traction wire and the object, the swinging frequency of the object is determined through frequency multiple scanning, and the swinging is prevented from being too large through detecting the swinging frequency between the object and the traction wire.
Further, the data processing module carries out signal transmission with the PLC through the focusing encoder communication unit for transmitting the instruction, and can quickly make data processing and judgment.
Further, the data processing module is provided with a PROFIBUS buffer zone, and the PROFIBUS buffer zone transmits data to the wireless communication unit WCU, so that the information reflecting rate is improved.
The method for the intelligent operation control system of the bridge crane comprises the following steps:
1) The method comprises the steps that coordinates of an object to be loaded are built through a position correction module, firstly, a coordinate measuring unit is used for determining the coordinates of the object after the object to be loaded is built through a coordinate system, an angle sensor is used for measuring and determining the inclined dragging angle of the object on the coordinate system, the traction angle is prevented from being overlarge, a distance sensor is used for measuring the distance between the moving position of the object and the coordinates, data are sent to a data processing module, the data are sent to a PLC after being processed, and speed adjustment is carried out on respective frequency converters;
2) The offset compensation sensor performs offset compensation on the offset actual coordinates, the coordinate guiding unit performs information real-time recording in the moving process, the coordinate guiding unit continuously performs data interaction with the PLC, the early warning unit performs early warning and alarming on the surrounding area of the crane, and the object is moved to the middle and lower part of the crane to perform object lifting work;
3) After the movement is completed, the anti-swing module firstly determines the weight of the object, records the acceleration of the crane accelerated to the maximum speed through the acceleration sensor, simultaneously determines the lifting height of the object through the weight, then sends an execution instruction of the PLC controller, moves the object, the tracking control unit records a moving path, makes speed adjustment for the moving process of the object by combining the frequency sensor, sends data to the data processing module through the output data of the sensors, and sends the data to the PLC controller after the data is processed, so as to make speed adjustment for respective frequency converters;
4) Meanwhile, the swinging prediction unit records the actual and predicted swinging paths of the object to reduce the swinging frequency of the object in the moving process, the amplitude modulation unit is used for sending the analyzed and processed data to the comparison unit, the comparison unit calculates through mechanical transmission gap data and transmits ultrasonic pulse information to compare the swinging time interval in the data with the preset time interval, and the PLC controller makes data adjustment.
Compared with the prior art, the invention has the beneficial effects that:
1. the design scheme is simple, the application field is wide, the installation period is short, and the requirements of the production and manufacturing industry on safety, efficiency and reliability can be met;
3. when the crane is used for carrying objects in the equipment, the swing amplitude of the objects is controlled through the square swing module, and the swing phenomenon of the crane is eliminated.
4. The equipment is internally provided with an external pulling and oblique dragging preventing function which is always required by the industry, and the allowed maximum angle can be set by a user according to the industry requirement;
5. the built-in automatic centering function of the equipment can automatically adjust the crane to the position above the load to be lifted, and the use standard of the crane in the use link in the industry is met.
6. The built-in area management function of the equipment can effectively standardize the use place of the user, for example, a forbidden zone of the equipment is planned, and the use functions which cannot be achieved by the traditional limit are completed;
7. the center function of the built-in area of the equipment can meet the requirement that a user has a fixed repeated center point in a use place, so that the normal production and manufacturing are more efficient.
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FIG. 1 is a functional diagram of a system of the present invention;
fig. 2 is a system block diagram of the present invention.
Detailed Description
Examples
As shown in fig. 1 and 2, the technical scheme of the invention is an intelligent operation control system of a bridge crane, which mainly comprises a position correction module, an anti-swing module, a data processing module and a PLC controller;
the position correction comprises a coordinate measuring unit, a distance sensing sensor, an offset compensation sensor, an angle sensor and a coordinate guiding unit; the coordinate measuring unit is used for establishing coordinates to carry out position marking on the operation of the object; the distance sensing sensor is used for measuring the set distance of the object moving position from the distance coordinate; the offset compensation unit is used for offset compensation of the actual coordinates; the angle sensor is used for measuring the inclined dragging angle of the object on the crane coordinates; the coordinate guiding unit comprises a pulse coding signal and an activity type, and is used for transmitting the pulse coding signal to an object to determine moving process information and carrying out real-time adjustment; the coordinate guiding unit comprises a force sensor, wherein the force sensor is used for determining the recorded traction force of each coordinate, and the traction force of each coordinate is fed back and adjusted in real time through the data feedback unit;
the anti-swing module comprises an acceleration sensor, a height sensor, a swing prediction unit, a tracking control unit and a frequency sensor; the acceleration sensor is used for recording the acceleration of the crane accelerated to the maximum speed; the height sensor records the lifting height of the object; the swing prediction unit is used for recording the actual and predicted swing paths of the object; the tracking speed control unit is used for carrying out speed adjustment on the path recorded by the swinging prediction unit, the frequency sensor is used for recording the frequency when the object swings, the frequency sensor is arranged on the traction wire and the object, the swinging frequency of the object is determined through frequency multiple scanning, and the swinging is prevented from being overlarge through detecting the swinging frequency between the object and the traction wire; the swing module comprises an executing amplitude modulation unit, wherein the executing amplitude modulation unit is used for calculating mechanical transmission gap data, transmitting ultrasonic pulse information and comparing a swing time interval with a preset time interval in the data;
the data processing module comprises a receiving unit, a signal processing unit, a data quantization analysis unit and a PROFIBUS buffer area, wherein the receiving unit is used for receiving the position correction and anti-swing data and integrating and transmitting the received data to the signal processing unit; the signal processing unit is used for classifying the integrated data; the data quantitative analysis unit analyzes and evaluates the extracted data and sends the processed data to the PLC; the PROFIBUS buffer zone transmits data to the WCU of the wireless communication unit, so that the information reflecting rate is improved; the PLC controller is used for editing data of the cart frequency converter, the trolley frequency converter and the lifting frequency converter.
The control system comprises an early warning module, wherein the early warning module is used for warning and alarming surrounding areas of the crane, the early warning module comprises an area information acquisition unit, an infrared sensor and a setting unit, the area information acquisition unit is used for carrying out rapid scanning analysis modeling on information of a using site and transmitting the analyzed information to the PLC, and the infrared sensor is used for carrying out scanning positioning processing on the using site.
The method for the intelligent operation control system of the bridge crane comprises the following steps:
1) The method comprises the steps that coordinates of an object to be loaded are built through a position correction module, firstly, a coordinate measuring unit is used for determining the coordinates of the object after the object to be loaded is built through a coordinate system, an angle sensor is used for measuring and determining the inclined dragging angle of the object on the coordinate system, the traction angle is prevented from being overlarge, a distance sensor is used for measuring the distance between the moving position of the object and the coordinates, data are sent to a data processing module, the data are sent to a PLC after being processed, and speed adjustment is carried out on respective frequency converters;
2) The offset compensation sensor performs offset compensation on the offset actual coordinates, the coordinate guiding unit performs information real-time recording in the moving process, the coordinate guiding unit continuously performs data interaction with the PLC, the early warning unit performs early warning and alarming on the surrounding area of the crane, and the object is moved to the middle and lower part of the crane to perform object lifting work;
3) After the movement is completed, the anti-swing module firstly determines the weight of an object, records the acceleration of the crane accelerated to the maximum speed through the acceleration sensor, determines the lifting height of the object through the weight, then sends an execution instruction of the PLC controller, moves the object, the tracking control unit records a moving path, makes speed adjustment to the object moving process by combining the frequency sensor, and the swing amplitude = lifting height/g x acceleration x 0.05+ mechanical transmission gap through the output data of the sensor, when the mechanical transmission gap is 0, the swing amplitude of the lifting height 10m is as follows: 10/9.8x0.2x0.05+0= 0.0102m, sending the data to a data processing module, processing the data, and sending the processed data to a PLC controller, and respectively adjusting the speeds of a cart frequency converter, a trolley frequency converter and a lifting frequency converter;
4) Meanwhile, the swinging prediction unit records the actual and predicted swinging paths of the object to reduce the swinging frequency of the object in the moving process, the amplitude modulation unit is used for sending the analyzed and processed data to the comparison unit, the comparison unit calculates through mechanical transmission gap data and transmits ultrasonic pulse information to compare the swinging time interval in the data with the preset time interval, and the PLC controller makes data adjustment.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (4)
1. The intelligent operation control system of the bridge crane is characterized by mainly comprising a position correction module, an anti-swing module, a data processing module and a PLC;
the position correction module comprises a coordinate measuring unit, a distance sensing sensor, an offset compensation sensor, an angle sensor and a coordinate guiding unit; the coordinate measuring unit is used for establishing coordinates to carry out position marking on the operation of the object; the distance sensing sensor is used for measuring the set distance of the distance coordinates of the moving position of the object; the offset compensation sensor is used for offset compensation of the actual coordinates; the angle sensor is used for measuring the inclined dragging angle of the object on the crane coordinates; the coordinate guiding unit comprises a pulse coding signal and an activity type, and is used for transmitting the pulse coding signal to an object to determine moving process information and carrying out real-time adjustment;
the coordinate guiding unit comprises a force sensor, wherein the force sensor is used for determining the recorded traction force of each coordinate, and the traction force of each coordinate is fed back and adjusted in real time through the data feedback unit;
the anti-swing module comprises an acceleration sensor, a height sensor, a swing prediction unit, a tracking control unit and a frequency sensor; the acceleration sensor is used for recording the acceleration of the crane accelerated to the maximum speed; the height sensor records the rising height of the object; the swing prediction unit is used for recording the actual and predicted swing paths of the object; the tracking control unit is used for adjusting the speed of the path recorded by the swing prediction unit; the frequency sensor is used for recording the frequency when the object swings;
the anti-swing module comprises an executing amplitude modulation unit, wherein the executing amplitude modulation unit is used for sending the analyzed and processed data to a comparison unit, and the comparison unit is used for transmitting ultrasonic pulse information through mechanical transmission gap data calculation and comparing a swing time interval with a preset time interval in the data;
the data processing module comprises a receiving unit, a signal processing unit and a data quantization analysis unit, wherein the receiving unit is used for receiving the position correction and anti-swing data and integrating and transmitting the received data to the signal processing unit; the signal processing unit is used for classifying the integrated data; the data quantitative analysis unit analyzes and evaluates the extracted data and sends the processed data to the PLC; the PLC is used for editing data of the cart frequency converter, the trolley frequency converter and the lifting frequency converter;
the control system comprises an early warning module, wherein the early warning module is used for warning and alarming a surrounding area of the crane, the early warning module comprises an area information acquisition unit, an infrared sensor and a setting unit, the area information acquisition unit is used for carrying out rapid scanning analysis modeling on information of a using site and transmitting the analyzed information to a PLC (programmable logic controller), and the infrared sensor is used for carrying out scanning positioning processing on the using site;
the method for the intelligent operation control system of the bridge crane comprises the following steps:
the method comprises the steps of establishing coordinates of an object to be loaded through a position correction module, firstly, determining coordinates of the object after the coordinate measurement unit establishes the object to be loaded through a coordinate system, measuring and determining the inclined drag angle of the object on the coordinate system through an angle sensor, measuring the distance between the moving position of the object and the coordinates by a distance sensing sensor, transmitting data to a data processing module, transmitting the data to a PLC after processing, and performing speed adjustment on respective frequency converters;
the offset compensation sensor performs offset compensation on the offset actual coordinates, the coordinate guiding unit performs information real-time recording in the moving process, the coordinate guiding unit continuously performs data interaction with the PLC, the early warning unit performs early warning and alarming on the surrounding area of the crane, and the object is moved to the middle and lower part of the crane to perform object lifting work;
after the movement is completed, the anti-swing module firstly determines the weight of the object, records the acceleration of the crane accelerated to the maximum speed through the acceleration sensor, simultaneously determines the lifting height of the object through the weight, then sends an execution instruction of the PLC controller, moves the object, the tracking control unit records a moving path, makes speed adjustment for the moving process of the object by combining the frequency sensor, sends data to the data processing module through the output data of the sensors, and sends the data to the PLC controller after the data is processed, so as to make speed adjustment for respective frequency converters;
meanwhile, the swinging prediction unit records the actual and predicted swinging paths of the object to reduce the swinging frequency of the object in the moving process, the amplitude modulation unit is used for sending the analyzed and processed data to the comparison unit, the comparison unit calculates through mechanical transmission gap data and transmits ultrasonic pulse information to compare the swinging time interval in the data with the preset time interval, and the PLC controller makes data adjustment.
2. The intelligent operation control system of a bridge crane according to claim 1, wherein the frequency sensor is arranged on the traction wire and the object, and the object swinging frequency is determined by frequency multiple scans.
3. The intelligent operation control system of a bridge crane according to claim 1, wherein the data processing module is in signal transmission with the PLC controller through a focusing encoder communication unit for transmitting instructions.
4. An intelligent operation control system for a bridge crane according to claim 1, wherein the data processing module is provided with a PROFIBUS buffer which transmits data to the wireless communication unit WCU.
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| CN113682956B (en) * | 2021-07-19 | 2023-06-02 | 杭州大杰智能传动科技有限公司 | Material environment condition automatic identification and analysis method and system for intelligent tower crane |
| CN115167271A (en) * | 2022-07-28 | 2022-10-11 | 广州起重机械有限公司 | Target object hoisting method, system, equipment and medium based on PLC control |
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