CN113682960A - Visual tower crane control system and control method - Google Patents
Visual tower crane control system and control method Download PDFInfo
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- CN113682960A CN113682960A CN202111043086.2A CN202111043086A CN113682960A CN 113682960 A CN113682960 A CN 113682960A CN 202111043086 A CN202111043086 A CN 202111043086A CN 113682960 A CN113682960 A CN 113682960A
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- 238000000034 method Methods 0.000 title claims abstract description 31
- 238000001514 detection method Methods 0.000 claims abstract description 69
- 238000012544 monitoring process Methods 0.000 claims abstract description 11
- 238000005452 bending Methods 0.000 claims description 21
- 238000004891 communication Methods 0.000 claims description 18
- 229910000831 Steel Inorganic materials 0.000 claims description 16
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/46—Position indicators for suspended loads or for crane elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/48—Automatic control of crane drives for producing a single or repeated working cycle; Programme control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
Abstract
A visual tower crane control system and a control method relate to the technical field of building machinery control. The visual tower crane control system comprises a tower crane, a hanging object auxiliary supporting assembly, a safety monitoring assembly, a PC (personal computer) and a singlechip; the auxiliary supporting component for the hanging object comprises a camera A, a camera B, a camera C and a millimeter wave radar; the safety monitoring assembly comprises a laser ranging module, a flat arm deformation detection module, a tower body inclination detection module and a wind power detection module. A tower crane control method is applied to the visual tower crane control system and comprises a risk disposal method and a visual control method. According to the invention, the visual field and the obstacle distribution condition around the tower crane are obtained through the combination of the millimeter wave radar and the multiple cameras, and an operator can accurately grasp the environment information of the operation site based on the image obtained by the cameras and the radar map obtained by the millimeter wave radar, so that the tower crane can be remotely and accurately controlled in the ground control room, and the working intensity of the operator is reduced.
Description
Technical Field
The invention relates to the technical field of control of construction machinery, in particular to a visual tower crane control system and a control method.
Background
A conventional tower crane structure is shown in fig. 3, and includes a tower base 11, a tower body 12, a horizontal arm 13, a first driving device (not shown), a trolley 15, a second driving device (not shown), and a crane assembly. The tower footing 11 is fixedly installed on the ground. The tower body 12 is fixedly connected to the upper end of the tower footing 11. The flat arm 13 is rotatably connected to the upper end of the tower body 12 through a first driving device, the flat arm 13 rotates on a horizontal plane under the driving of the first driving device, the flat arm 13 is bounded by a rotation connection point, and a balance arm section 131 and a lifting arm section 132 are respectively arranged at two ends of the flat arm 13. The trolley 15 is movably connected to the jib section 132 of the flat arm 13 through a second driving device, and the trolley 15 is driven by the second driving device to do reciprocating linear motion along the jib section 132 of the flat arm 13. The object hanging component comprises a steel cable 171, a third driving device (not shown in the figure) and a lifting hook 173, the steel cable 171 is arranged at the lower end of the trolley 15 and is connected with the trolley 15 through the third driving device, the lifting hook is connected to the lower end of the steel cable 171, the take-up or pay-off of the steel cable 171 is controlled through the third driving device, and then the lifting hook 173 is controlled to do vertical lifting movement.
On one hand, a tower crane driver needs to control a tower crane in a trolley located in the high altitude, so that certain potential safety hazards exist in the high altitude operation of the driver, the high altitude operation spirit of the driver is in a highly tense state for a long time, and the driver is easy to feel tired; on the other hand, when the object is hung, the object is hung in an auxiliary way by means of visual observation of a driver, experience analysis of the driver, contact of ground personnel with the driver through an interphone and the like, the way is relatively extensive and original, and the efficiency and the success rate of the object hanging depend on the personal ability of the driver to a large extent; on the other hand, when the driver operates the tower crane to perform various actions, certain misoperation probability exists, and if the driver collides with an obstacle or hurts people due to misoperation, the result is unimaginable.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides a visual tower crane control system and a control method, and solves the problems that the existing tower crane control mode is relatively extensive and original, the efficiency of hoisting objects is difficult to guarantee, and a certain misoperation probability exists.
The technical scheme of the invention is as follows: the visual tower crane control system comprises a tower crane; the tower crane comprises a tower foundation, a tower body, a flat arm, a first driving device, a trolley, a second driving device and a hanging component; the tower footing is fixedly arranged on the ground; the tower body is fixedly connected to the upper end of the tower footing; the horizontal arm is rotatably connected to the upper end of the tower body through a first driving device, the horizontal arm is driven by the first driving device to rotate on the horizontal plane, the horizontal arm is bounded by a rotating connection point, and a balance arm section and a lifting arm section are respectively arranged at two ends of the horizontal arm; the trolley is movably connected to the jib section of the flat arm through a second driving device and is driven by the second driving device to do reciprocating linear motion along the jib section of the flat arm; the object hanging component comprises a steel cable, a third driving device and a lifting hook, the steel cable is arranged at the lower end of the trolley and is associated with the trolley through the third driving device, the lifting hook is connected to the lower end of the steel cable, and the third driving device controls the steel cable to take up or pay off so as to control the lifting hook to vertically move;
the system also comprises a hanging auxiliary supporting component, a safety monitoring component, a PC and a singlechip;
the auxiliary supporting component for the hanging object comprises a camera A, a camera B, a camera C and a millimeter wave radar; the camera A is arranged on the tower body and used for acquiring the ground and aerial visual field around the tower body, the camera B is arranged at the lower end of the crane arm section and used for acquiring the visual field of the lower area of the crane arm section, and the camera C is arranged at the lower end of the trolley and used for acquiring the visual field right below the lifting hook and the lifting hook; the millimeter wave radar is installed at the lower end of the crane arm section and used for acquiring the obstacle distribution condition of the lower area of the crane arm section;
the safety monitoring assembly comprises a laser ranging module, a flat arm deformation detection module, a tower body inclination detection module and a wind power detection module; the two laser ranging modules are respectively arranged on two opposite side walls of the flat-arm crane jib section, and the light emitting directions of the two laser ranging modules are parallel to the crane jib section and extend towards the tail end of the crane jib section, and the two laser ranging modules are used for detecting whether barriers exist on the rotation path of the crane jib section; the flat arm deformation detection module is arranged at the lower end of the crane arm section and is used for detecting the bending deformation degree of the crane arm section; the tower body inclination detection module is arranged on the tower body and used for detecting the bending deformation degree of the tower body; the wind power detection module is arranged on the tower body and/or the flat arm and is used for detecting the wind power level;
the PC is respectively in communication connection with the camera A, the camera B, the camera C and the millimeter wave radar and is used for visually displaying images acquired by the camera A, the camera B and the camera C and radar data acquired by the millimeter wave radar;
the signal input end of the single chip microcomputer is in communication connection with the laser ranging module, the flat arm deformation detection module, the tower body inclination detection module and the wind power detection module respectively, and the signal output end of the single chip microcomputer is in communication connection with the first driving device, the second driving device, the third driving device and the PC respectively.
The further technical scheme of the invention is as follows: the PC also comprises a quick frame grabber and an image edge calculation module; the fast frame grabber is respectively in communication connection with the camera A, the camera B and the camera C so as to capture each frame of a video image shot by the camera A, the camera B and the camera C; the image edge calculation module is in communication connection with the fast frame grabber so as to perform object contour tracing processing on the frame pictures extracted by the fast frame grabber.
The technical scheme of the invention is as follows: a tower crane control method is applied to the visual tower crane control system and comprises a risk disposal method and a visual control method;
the visual control method comprises the following steps:
a. the method comprises the steps that the ground and aerial visual fields around a lifted object are obtained through a camera A and a camera B, the visual fields right below a lifting hook and the lifting hook are obtained through a camera C, and a radar chart of the distribution situation of obstacles around the lifted object is obtained through a millimeter wave radar;
b. the detection ranges of the camera A, the camera B, the camera C and the millimeter wave radar are all conical, the vertex of each cone is the position of the camera A, the camera B, the camera C and the millimeter wave radar, and the included angle formed by the central line of each cone and the horizontal plane is the detection angle; if so, the detection angle of the camera A is larger than that of the camera B, the detection angle of the camera C is 90 degrees, and the detection angle of the millimeter wave radar is the same as that of the camera A;
c. images shot by the camera A, the camera B and the camera C and radar maps obtained by the millimeter wave radar are displayed in real time in different areas of one display connected with the PC, or are respectively displayed on a plurality of displays connected with the PC;
the risk management method is as follows:
a. detecting the wind power level around the tower crane in real time through a wind power detection module, and transmitting the detection result to a PC (personal computer) through a single chip microcomputer; when the wind power is higher than 6 levels, the PC sends out early warning to prompt an operator to stop the tower crane operation; when the wind power is more than 8 grades, the first driving device, the second driving device and the third driving device of the tower crane are directly controlled by the single chip microcomputer to stop running, so that the tower crane stops running;
b. detecting the inclination angle of the tower body in real time through a tower body inclination detection module, defining the inclination angle as an included angle formed by the tower body and a vertical plane, and setting the inclination angle as r, wherein the r is 0 degree under the condition that the tower crane is in no load; when the range of r is more than minus 0.2 degrees and less than 0.2 degrees, the inclination angle of the tower body is in the safety value range; when r is more than or equal to 1 degree or r is less than or equal to minus 1 degree, the first driving device, the second driving device and the third driving device of the tower crane are directly controlled by the single chip microcomputer to stop running, so that the tower crane stops running; when r is more than-1 degree and less than or equal to-0.2 degree or more than or equal to 0.2 degree and less than 1 degree, the PC machine sends out early warning to prompt an operator to stop the tower crane operation;
c. the bending deformation degree of the crane jib section is detected in real time through a flat jib deformation detection module, the flat jib deformation detection module is a pressure sensor, the pressure sensor is installed at the lower end of the middle part of the crane jib section, the distance from the pressure sensor to the tail end of the crane jib section is 1/3 of the total length of the crane jib section, an alarm threshold value and a shutdown threshold value are set through a single chip microcomputer, and the alarm threshold value is smaller than the shutdown threshold value; when the tower crane is unloaded, the hoisting arm section only generates downward bending deformation under the self weight, when the tower crane hoists an object, the bending deformation degree of the hoisting arm section under the combined action of the hoisted object and the self weight is increased, the pressure applied to the pressure sensor is correspondingly increased, and the detection value of the pressure sensor is correspondingly increased;
setting the detection value of the pressure sensor as F, when F is more than 0 and less than a, the bending deformation degree of the lifting arm section is in a safety range, when a is more than or equal to F and less than b, sending out an early warning by a PC (personal computer) to remind an operator to stop the tower crane operation, and when F is more than or equal to b, simultaneously executing the following control by a singlechip: 1. controlling the first driving device to stop running so as to stop the rotation of the flat arm; 2. controlling the second driving device to act, and moving the trolley to an extreme position far away from the tail end of the crane arm section so as to reduce the bending deformation degree of the crane arm section; 3. controlling the third driving device to act to lower the lifting hook and place the lifted object back on the ground;
d. detecting whether an obstacle exists on a rotation path of the crane arm section through a laser ranging module, setting the inherent distance from the laser ranging module to the tail end of the crane arm section as s, and setting the ranging value of the laser ranging module as h, wherein when h is larger than s, the obstacle does not exist on the rotation path of the crane arm section, and when h is smaller than or equal to s, the obstacle exists on the rotation path of the crane arm section;
the two laser ranging modules start ranging at the same time, and the laser ranging module with a relatively small ranging value at the same time point is used as a judgment reference; when h is larger than s + p, the crane arm section cannot collide with an obstacle in the rotating process; when h is less than or equal to s + p, the risk that the crane arm section collides with an obstacle exists in the rotating process is shown, the singlechip controls the first driving device to stop running, and the flat arm stops rotating;
and p is a safe distance and has a value range of 0.1-0.5 m.
The invention further adopts the technical scheme that: the fast frame grabber grabs frame pictures in the images shot by the camera A, the camera B and the camera C, the frame pictures are subjected to object contour tracing processing through the image edge calculation module, and finally the pictures subjected to object contour tracing processing are displayed through a display of the PC; the object outline tracing process takes the shape of an object in a picture or the color threshold change in the picture as a constraint condition.
Compared with the prior art, the invention has the following advantages:
1. through the combination of millimeter wave radar and a plurality of camera, acquire the peripheral field of vision of tower crane and barrier distribution condition, operating personnel can pinpoint the material and hold operation site environment information based on the image that the camera obtained and the radar map that the millimeter wave radar acquireed, and then just can carry out long-range accurate efficient to the tower crane and control in ground control room, reduced operating personnel's working strength.
2. The operation state information and the external environment information of the tower crane are monitored through the safety monitoring assembly, a whole set of complete risk early warning and disposal flow is established, an operator is helped to know the state information of the tower crane in real time, the safety work of the tower crane is ensured, and the safety of the tower crane operation is greatly improved.
The invention is further described below with reference to the figures and examples.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic diagram of the communication connections of the various components of the present invention;
fig. 3 is a schematic diagram of the structure of the existing tower crane.
Illustration of the drawings: a tower footing 11; a tower body 12; a flat arm 13; a balance arm segment 131; a boom segment 132; a first drive device 14; a trolley 15; a second drive device 16; a wire rope 171; a third drive 172; a hook 173; camera a 21; a camera B22; camera C23; a millimeter-wave radar 24; a laser ranging module 31; a flat arm deformation detection module 32; a tower inclination detection module 33; a wind detection module 34; a PC machine 4; a fast frame grabber 41; an image edge calculation module 42; and the singlechip 5.
Detailed Description
Example 1:
as shown in fig. 1-2, the visual tower crane control system comprises a tower crane, a hanging object auxiliary supporting assembly, a safety monitoring assembly, a PC and a single chip microcomputer.
The tower crane comprises a tower foundation 11, a tower body 12, a flat arm 13, a first driving device 14, a trolley 15, a second driving device 16 and a hanging object assembly. The tower footing 11 is fixedly installed on the ground. The tower body 12 is fixedly connected to the upper end of the tower footing 11. The flat arm 13 is rotatably connected to the upper end of the tower 12 through a first driving device 14, the flat arm 13 is driven by the first driving device 14 to rotate in a horizontal plane, the flat arm 13 is bounded by a rotation connection point, and two ends of the flat arm 13 are a balance arm section 131 and a lifting arm section 132 respectively. The trolley 15 is movably connected to the jib section 132 of the flat arm 13 through the second driving device 16, and the trolley 15 is driven by the second driving device 16 to make reciprocating linear motion along the jib section 132 of the flat arm 13. The object hanging component comprises a steel cable 171, a third driving device 172 and a lifting hook 173, the steel cable 171 is arranged at the lower end of the trolley 15 and is associated with the trolley 15 through the third driving device 172, the lifting hook 173 is connected to the lower end of the steel cable 171, the wire taking-up or paying-off of the steel cable 171 is controlled through the third driving device 172, and then the lifting hook 173 is controlled to move vertically.
The auxiliary supporting assembly for the hanging object comprises a camera A21, a camera B22, a camera C23 and a millimeter wave radar 24. A camera a21 is mounted on the tower 12 for capturing ground and air views around the tower 12, a camera B22 is mounted at the lower end of the jib portion 132 for capturing a view of the lower region of the jib portion 132, and a camera C23 is mounted at the lower end of the trolley 15 for capturing a view directly below the hook 173 and the hook 173. The millimeter wave radar 24 is installed at the lower end of the boom section 132, and is used for acquiring the obstacle distribution condition of the lower area of the boom section 132.
The safety monitoring assembly comprises a laser ranging module 31, a flat arm deformation detection module 32, a tower body inclination detection module 33 and a wind power detection module 34. The two laser ranging modules 31 are respectively installed on two opposite side walls of the jib section 132 of the flat arm 13, and light emitting directions of the two laser ranging modules 31 are both parallel to the jib section 132 and extend towards the tail end of the jib section 132, and the two laser ranging modules are used for detecting whether an obstacle exists on a rotation path of the jib section 132. The flat arm deformation detection module 32 is mounted at the lower end of the jib portion 132 and is used for detecting the bending deformation degree of the jib portion 132. The tower inclination detection module 33 is mounted on the tower 12, and detects the degree of bending deformation of the tower 12. A wind detection module 34 is mounted on the tower 12 for detecting the wind level.
The PC 4 is in communication connection with the camera a21, the camera B22, the camera C23 and the millimeter wave radar 24 respectively, and is used for visually displaying images acquired by the camera a21, the camera B22 and the camera C23 and radar data acquired by the millimeter wave radar 24.
The signal input end of the single chip microcomputer 5 is respectively in communication connection with the laser ranging module 31, the flat arm deformation detection module 32, the tower inclination detection module 33 and the wind power detection module 34, and the signal output end of the single chip microcomputer 5 is respectively in communication connection with the first driving device 14, the second driving device 16, the third driving device 172 and the PC 4. The single chip microcomputer 5 is in communication connection with the first driving device 14, the second driving device 16 and the third driving device 172 and is used for controlling the running state of the tower crane, and the single chip microcomputer 5 is in communication connection with the PC 4 and is used for visually displaying monitoring data acquired by the safety monitoring assembly on the PC 4.
Preferably, the camera a21, the camera B22 and the camera C23 are all network cameras with built-in 4G modules.
Preferably, the PC 4 comprises a fast frame grabber 41 and an image edge calculation module 42, and the PC 4 is in communication connection with the cameras a21, B22 and C23 through the fast frame grabber 41 respectively to capture each frame of the video images captured by the cameras a21, B22 and C23. The image edge calculation module 42 is in communication connection with the fast frame grabber 41 to perform object contour delineation processing on the frame picture extracted by the fast frame grabber 41.
Preferably, the fast frame grabber 41 is of the type IMPERX _ VCE-CLEX01, and the image edge calculation module 42 is of the type NVIDIA JETSON TX 2.
Preferably, the model of the singlechip 5 is stm32f103zet 6.
A tower crane control method is applied to the visual tower crane control system and comprises a risk disposal method and a visual control method.
The visual control method comprises the following steps:
a. the ground and air visual fields around the lifted object are acquired through the camera A21 and the camera B22, the visual fields right below the lifting hook 173 and the lifting hook 173 are acquired through the camera C23, and the radar map of the obstacle distribution around the lifted object is acquired through the millimeter wave radar.
b. The detection ranges of the camera A21, the camera B22, the camera C23 and the millimeter wave radar 24 are all conical, the vertex of each cone is the position of the camera A21, the camera B22, the camera C23 and the millimeter wave radar 24, and the included angle formed by the central line of each cone and the horizontal plane is a detection angle; then, the detection angle of the camera a21 is larger than that of the camera B22, the detection angle of the camera C23 is 90 °, and the detection angle of the millimeter wave radar 24 is the same as that of the camera a 21.
c. The images captured by the camera a21, the camera B22, the camera C23, and the radar chart obtained by the millimeter wave radar 24 are displayed in real time in different areas of one display connected to the PC 4, or are displayed separately on a plurality of displays connected to the PC 4.
The risk management method is as follows:
a. the wind power level of the periphery of the tower crane is detected in real time through a wind power detection module 34, and the detection result is transmitted to a PC (personal computer) 4 through a singlechip 5; when the wind power is higher than 6 levels, the PC 4 gives out early warning to prompt an operator to stop the tower crane operation; when the wind power is greater than 8 levels, the singlechip 5 directly controls the first driving device 14, the second driving device 16 and the third driving device 172 of the tower crane to stop running, so that the tower crane stops running.
b. Detecting the inclination angle of the tower body 12 in real time through the tower body inclination detection module 33, defining the inclination angle as an included angle formed by the tower body 12 and a vertical plane, and setting the inclination angle as r, wherein the r is 0 degree under the condition that the tower crane is unloaded (namely, objects are not hoisted on the lifting hook 173); when the range of r is more than minus 0.2 degrees and less than 0.2 degrees, the inclination angle of the tower body 12 is in the safety value range; when r is more than or equal to 1 degree or less than or equal to minus 1 degree, the singlechip 5 directly controls the first driving device 14, the second driving device 16 and the third driving device 172 of the tower crane to stop running, so that the tower crane stops running; when r is more than 1 degree and less than or equal to 0.2 degree or more than or equal to 0.2 degree and less than 1 degree, the PC machine 4 sends out early warning (alarm information is displayed on a display connected with the PC machine) to prompt an operator to stop the tower crane operation.
c. The bending deformation degree of the crane arm section 132 is detected in real time through the flat arm deformation detection module 32, the flat arm deformation detection module 32 is a pressure sensor, the pressure sensor is installed at the lower end of the middle part of the crane arm section 132, the distance from the tail end of the crane arm section 132 is 1/3 of the total length of the crane arm section 132, an alarm threshold value and a shutdown threshold value are set through the single chip microcomputer 5, and the alarm threshold value is smaller than the shutdown threshold value; when the tower crane is unloaded, the crane arm section 132 only generates downward bending deformation under the self weight, when the tower crane lifts an object, the bending deformation degree of the crane arm section 132 under the combined action of the lifted object and the self weight is increased, the pressure applied to the pressure sensor is correspondingly increased, and the detection numerical value of the pressure sensor is correspondingly increased;
setting the detection value of the pressure sensor as F, when F is more than 0 and less than a, the bending deformation degree of the lifting arm section is in a safety range, when a is more than or equal to F and less than b, sending out an early warning by a PC (personal computer) to remind an operator to stop the tower crane operation, and when F is more than or equal to b, simultaneously executing the following control by a singlechip: 1. controlling the first driving device 14 to stop running so as to stop the rotation of the flat arm 13; 2. controlling the second driving device 16 to move the trolley 15 to an extreme position far away from the end of the jib section 132 so as to reduce the bending deformation degree of the jib section 132; 3. controlling the third driving device 172 to move so that the hook 173 is lowered, and the hung object is placed back on the ground;
when the tower crane lifts the object with the maximum weight allowed to be lifted, the pressure applied to the pressure sensor is the stop threshold value; when the tower crane lifts the object which is 80% of the maximum weight allowed to be lifted, the pressure applied to the pressure sensor is the alarm threshold value.
d. Whether an obstacle exists on the rotation path of the jib section 132 is detected through the laser ranging module 31, the inherent distance from the laser ranging module 31 to the tail end of the jib section 132 is set to be s, the ranging value of the laser ranging module 31 is set to be h, when h is larger than s, the obstacle does not exist on the rotation path of the jib section 132, and when h is smaller than or equal to s, the obstacle exists on the rotation path of the jib section 132;
the two laser ranging modules 31 start ranging at the same time, and the laser ranging module 31 with a relatively small ranging value at the same time point is used as a judgment reference; when h > s + p, it means that the boom segment 132 does not hit an obstacle during rotation; when h is less than or equal to s + p, the crane arm section 132 is indicated to have the risk of colliding with an obstacle in the rotating process, the singlechip 5 controls the first driving device 14 to stop running, and the flat arm 13 stops rotating; and p is a safe distance and has a value range of 0.1-0.5 m.
Preferably, after the fast frame grabber 41 grabs the frame pictures in the images shot by the camera a21, the camera B22 and the camera C23, the image edge calculation module 42 performs object contour edge tracing on the frame pictures, and finally the display of the PC displays the pictures after the object contour edge tracing; the object outline tracing process takes the shape of an object in a picture or the color threshold change in the picture as a constraint condition.
Claims (4)
1. The visual tower crane control system comprises a tower crane; the tower crane comprises a tower foundation, a tower body, a flat arm, a first driving device, a trolley, a second driving device and a hanging component; the tower footing is fixedly arranged on the ground; the tower body is fixedly connected to the upper end of the tower footing; the horizontal arm is rotatably connected to the upper end of the tower body through a first driving device, the horizontal arm is driven by the first driving device to rotate on the horizontal plane, the horizontal arm is bounded by a rotating connection point, and a balance arm section and a lifting arm section are respectively arranged at two ends of the horizontal arm; the trolley is movably connected to the jib section of the flat arm through a second driving device and is driven by the second driving device to do reciprocating linear motion along the jib section of the flat arm; the object hanging component comprises a steel cable, a third driving device and a lifting hook, the steel cable is arranged at the lower end of the trolley and is associated with the trolley through the third driving device, the lifting hook is connected to the lower end of the steel cable, and the third driving device controls the steel cable to take up or pay off so as to control the lifting hook to vertically move;
the system is characterized by also comprising a hanging auxiliary supporting component, a safety monitoring component, a PC and a singlechip;
the auxiliary supporting component for the hanging object comprises a camera A, a camera B, a camera C and a millimeter wave radar; the camera A is arranged on the tower body and used for acquiring the ground and aerial visual field around the tower body, the camera B is arranged at the lower end of the crane arm section and used for acquiring the visual field of the lower area of the crane arm section, and the camera C is arranged at the lower end of the trolley and used for acquiring the visual field right below the lifting hook and the lifting hook; the millimeter wave radar is installed at the lower end of the crane arm section and used for acquiring the obstacle distribution condition of the lower area of the crane arm section;
the safety monitoring assembly comprises a laser ranging module, a flat arm deformation detection module, a tower body inclination detection module and a wind power detection module; the two laser ranging modules are respectively arranged on two opposite side walls of the flat-arm crane jib section, and the light emitting directions of the two laser ranging modules are parallel to the crane jib section and extend towards the tail end of the crane jib section, and the two laser ranging modules are used for detecting whether barriers exist on the rotation path of the crane jib section; the flat arm deformation detection module is arranged at the lower end of the crane arm section and is used for detecting the bending deformation degree of the crane arm section; the tower body inclination detection module is arranged on the tower body and used for detecting the bending deformation degree of the tower body; the wind power detection module is arranged on the tower body and used for detecting the wind power level;
the PC is respectively in communication connection with the camera A, the camera B, the camera C and the millimeter wave radar and is used for visually displaying images acquired by the camera A, the camera B and the camera C and radar data acquired by the millimeter wave radar;
the signal input end of the single chip microcomputer is in communication connection with the laser ranging module, the flat arm deformation detection module, the tower body inclination detection module and the wind power detection module respectively, and the signal output end of the single chip microcomputer is in communication connection with the first driving device, the second driving device, the third driving device and the PC respectively.
2. The visual tower crane control system of claim 1, characterized in that: the PC also comprises a quick frame grabber and an image edge calculation module; the fast frame grabber is respectively in communication connection with the camera A, the camera B and the camera C so as to capture each frame of a video image shot by the camera A, the camera B and the camera C; the image edge calculation module is in communication connection with the fast frame grabber so as to perform object contour tracing processing on the frame pictures extracted by the fast frame grabber.
3. A tower crane control method is applied to the visual tower crane control system of claim 2, and comprises a risk disposal method and a visual control method;
the visual control method comprises the following steps:
a. the method comprises the steps that the ground and aerial visual fields around a lifted object are obtained through a camera A and a camera B, the visual fields right below a lifting hook and the lifting hook are obtained through a camera C, and a radar chart of the distribution situation of obstacles around the lifted object is obtained through a millimeter wave radar;
b. the detection ranges of the camera A, the camera B, the camera C and the millimeter wave radar are all conical, the vertex of each cone is the position of the camera A, the camera B, the camera C and the millimeter wave radar, and the included angle formed by the central line of each cone and the horizontal plane is the detection angle; if so, the detection angle of the camera A is larger than that of the camera B, the detection angle of the camera C is 90 degrees, and the detection angle of the millimeter wave radar is the same as that of the camera A;
c. images shot by the camera A, the camera B and the camera C and radar maps obtained by the millimeter wave radar are displayed in real time in different areas of one display connected with the PC, or are respectively displayed on a plurality of displays connected with the PC;
the risk management method is as follows:
a. detecting the wind power level around the tower crane in real time through a wind power detection module, and transmitting the detection result to a PC (personal computer) through a single chip microcomputer; when the wind power is higher than 6 levels, the PC sends out early warning to prompt an operator to stop the tower crane operation; when the wind power is more than 8 grades, the first driving device, the second driving device and the third driving device of the tower crane are directly controlled by the single chip microcomputer to stop running, so that the tower crane stops running;
b. detecting the inclination angle of the tower body in real time through a tower body inclination detection module, defining the inclination angle as an included angle formed by the tower body and a vertical plane, and setting the inclination angle as r, wherein the r is 0 degree under the condition that the tower crane is in no load; when the range of r is more than minus 0.2 degrees and less than 0.2 degrees, the inclination angle of the tower body is in the safety value range; when r is more than or equal to 1 degree or r is less than or equal to minus 1 degree, the first driving device, the second driving device and the third driving device of the tower crane are directly controlled by the single chip microcomputer to stop running, so that the tower crane stops running; when r is more than-1 degree and less than or equal to-0.2 degree or more than or equal to 0.2 degree and less than 1 degree, the PC machine sends out early warning to prompt an operator to stop the tower crane operation;
c. the bending deformation degree of the crane jib section is detected in real time through a flat jib deformation detection module, the flat jib deformation detection module is a pressure sensor, the pressure sensor is installed at the lower end of the middle part of the crane jib section, the distance from the pressure sensor to the tail end of the crane jib section is 1/3 of the total length of the crane jib section, an alarm threshold value and a shutdown threshold value are set through a single chip microcomputer, and the alarm threshold value is smaller than the shutdown threshold value; when the tower crane is unloaded, the hoisting arm section only generates downward bending deformation under the self weight, when the tower crane hoists an object, the bending deformation degree of the hoisting arm section under the combined action of the hoisted object and the self weight is increased, the pressure applied to the pressure sensor is correspondingly increased, and the detection value of the pressure sensor is correspondingly increased;
setting the detection value of the pressure sensor as F, when F is more than 0 and less than a, the bending deformation degree of the lifting arm section is in a safety range, when a is more than or equal to F and less than b, sending out an early warning by a PC (personal computer) to remind an operator to stop the tower crane operation, and when F is more than or equal to b, simultaneously executing the following control by a singlechip: 1. controlling the first driving device to stop running so as to stop the rotation of the flat arm; 2. controlling the second driving device to act, and moving the trolley to an extreme position far away from the tail end of the crane arm section so as to reduce the bending deformation degree of the crane arm section; 3. controlling the third driving device to act to lower the lifting hook and place the lifted object back on the ground;
d. detecting whether an obstacle exists on a rotation path of the crane arm section through a laser ranging module, setting the inherent distance from the laser ranging module to the tail end of the crane arm section as s, and setting the ranging value of the laser ranging module as h, wherein when h is larger than s, the obstacle does not exist on the rotation path of the crane arm section, and when h is smaller than or equal to s, the obstacle exists on the rotation path of the crane arm section;
the two laser ranging modules start ranging at the same time, and the laser ranging module with a relatively small ranging value at the same time point is used as a judgment reference; when h is larger than s + p, the crane arm section cannot collide with an obstacle in the rotating process; when h is less than or equal to s + p, the risk that the crane arm section collides with an obstacle exists in the rotating process is shown, the singlechip controls the first driving device to stop running, and the flat arm stops rotating;
and p is a safe distance and has a value range of 0.1-0.5 m.
4. The tower crane control method according to claim 3, characterized in that: the fast frame grabber grabs frame pictures in the images shot by the camera A, the camera B and the camera C, the frame pictures are subjected to object contour tracing processing through the image edge calculation module, and finally the pictures subjected to object contour tracing processing are displayed through a display of the PC; the object outline tracing process takes the shape of an object in a picture or the color threshold change in the picture as a constraint condition.
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