CN113682960B - Visualized tower crane control system and control method - Google Patents

Visualized tower crane control system and control method Download PDF

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Publication number
CN113682960B
CN113682960B CN202111043086.2A CN202111043086A CN113682960B CN 113682960 B CN113682960 B CN 113682960B CN 202111043086 A CN202111043086 A CN 202111043086A CN 113682960 B CN113682960 B CN 113682960B
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camera
driving device
crane
tower
tower crane
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CN113682960A (en
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邢铭涵
王湘江
王浩源
梁继烨
袁克凯
黎泽庭
黄予
曾宪睿
郑军斌
陆瀚元
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University of South China
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00Other constructional features or details
    • B66C13/16Applications of indicating, registering, or weighing devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00Other constructional features or details
    • B66C13/18Control systems or devices
    • B66C13/46Position indicators for suspended loads or for crane elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00Other constructional features or details
    • B66C13/18Control systems or devices
    • B66C13/48Automatic control of crane drives for producing a single or repeated working cycle; Program control
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B66HOISTING; LIFTING; HAULING
    • B66CCRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C15/00Safety gear

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Control And Safety Of Cranes (AREA)

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 suspended object auxiliary support component, a safety monitoring component, a PC (personal computer) and a singlechip; the suspended object auxiliary support component 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 treatment method and a visual control method. According to the invention, through the combination of the millimeter wave radar and the cameras, the view field and the obstacle distribution situation around the crane are obtained, and the operator can accurately grasp the environment information of the operation site based on the images obtained by the cameras and the radar images obtained by the millimeter wave radar, so that the crane can be accurately controlled remotely in a ground control room, and the working intensity of the operator is reduced.

Description

可视化塔吊控制系统及控制方法Visual tower crane control system and control method

技术领域Technical field

本发明涉及建筑机械控制技术领域,特别是一种可视化塔吊控制系统及控制方法。The invention relates to the technical field of construction machinery control, in particular to a visual tower crane control system and a control method.

背景技术Background technique

目前常见的塔吊结构如图3所示,包括塔基11、塔身12、平臂13、第一驱动装置(图中未示出)、小车15、第二驱动装置(图中未示出)和吊物组件。塔基11固定安装在地面上。塔身12固定连接在塔基11上端。平臂13通过第一驱动装置可转动的连接在塔身12上端,平臂13在第一驱动装置的驱动下做水平面上的转动,平臂13以转动连接点为界,两端分别为平衡臂段131和起重臂段132。小车15通过第二驱动装置活动连接在平臂13的起重臂段132上,小车15在第二驱动装置的驱动下沿着平臂13的起重臂段132做往复直线运动。吊物组件包括钢缆171、第三驱动装置(图中未示出)和吊钩173,钢缆171设置在小车15下端,并通过第三驱动装置与小车15关联,吊钩连接在钢缆171下端,通过第三驱动装置控制钢缆171的收线或放线,进而控制吊钩173做竖直升降移动。The currently common tower crane structure is shown in Figure 3, including a tower base 11, a tower body 12, a flat arm 13, a first driving device (not shown in the figure), a trolley 15, and a second driving device (not shown in the figure). and lifting components. The tower base 11 is fixedly installed on the ground. The tower body 12 is fixedly connected to the upper end of the tower base 11 . The flat arm 13 is rotatably connected to the upper end of the tower body 12 through the first driving device. The flat arm 13 is driven by the first driving device to rotate on the horizontal plane. The flat arm 13 is bounded by the rotation connection point, and the two ends are balanced. Boom section 131 and boom section 132. The trolley 15 is movably connected to the boom section 132 of the flat arm 13 through the second driving device, and the trolley 15 makes a reciprocating linear motion along the boom section 132 of the flat arm 13 driven by the second driving device. The hanging object assembly includes a steel cable 171, a third driving device (not shown in the figure) and a 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. The hook is connected to the steel cable. 171 lower end, the third driving device controls the take-up or pay-out of the steel cable 171, and then controls the vertical lifting movement of the hook 173.

塔吊驾驶员需在位于高空的小车中控制塔吊,一方面,驾驶员高空作业存在一定的安全隐患,驾驶员高空作业精神长时间处于高度紧张状态,容易产生疲劳感;另一方面,吊取物件时,通常是通过驾驶员本人肉眼观察、驾驶员本人经验分析、地面人员通过对讲机联络驾驶员等方式辅助吊取物件,这种方式比较粗放和原始,吊取物件的效率和成功率较大程度上依赖驾驶员的个人能力;再一方面,驾驶员操控塔吊执行各种动作的时候存在一定的误操作几率,若因误操作撞到障碍物或伤害到人,后果不堪设想。The tower crane driver needs to control the tower crane from a trolley at high altitude. On the one hand, there are certain safety risks for the driver when working at high altitude. The driver's spirit of working at high altitude is in a state of high tension for a long time, which is prone to fatigue; on the other hand, lifting objects Usually, the driver's visual observation, the driver's own experience analysis, and the ground personnel contacting the driver through the intercom are used to assist in lifting the object. This method is relatively extensive and primitive, and the efficiency and success rate of lifting the object are relatively high. On the other hand, there is a certain probability of misoperation when the driver controls the tower crane to perform various actions. If the driver hits an obstacle or injures someone due to misoperation, the consequences will be disastrous.

发明内容Contents of the invention

本发明的目的是克服现有技术的不足,而提供一种可视化塔吊控制系统及控制方法,它解决了目前的塔吊控制方式比较粗放和原始,吊运物件的效率难以保障,存在一定的误操作几率的问题。The purpose of the present invention is to overcome the shortcomings of the existing technology and provide a visual tower crane control system and control method, which solves the problem that the current tower crane control method is relatively extensive and primitive, the efficiency of lifting objects is difficult to guarantee, and there are certain misoperations. A matter of probability.

本发明的技术方案是:可视化塔吊控制系统,包括塔吊;塔吊包括塔基、塔身、平臂、第一驱动装置、小车、第二驱动装置和吊物组件;塔基固定安装在地面上;塔身固定连接在塔基上端;平臂通过第一驱动装置可转动的连接在塔身上端,平臂在第一驱动装置的驱动下做水平面上的转动,平臂以转动连接点为界,两端分别为平衡臂段和起重臂段;小车通过第二驱动装置活动连接在平臂的起重臂段上,小车在第二驱动装置的驱动下沿着平臂的起重臂段做往复直线运动;吊物组件包括钢缆、第三驱动装置和吊钩,钢缆设置在小车下端,并通过第三驱动装置与小车关联,吊钩连接在钢缆下端,通过第三驱动装置控制钢缆的收线或放线,进而控制吊钩做竖直升降移动;The technical solution of the present invention is: a visual tower crane control system, including a tower crane; the tower crane includes a tower base, a tower body, a flat arm, a first driving device, a trolley, a second driving device and a hanging object assembly; the tower base is fixedly installed on the ground; The tower body is fixedly connected to the upper end of the tower base; the flat arm is rotatably connected to the upper end of the tower body through the first driving device. The flat arm rotates on the horizontal plane driven by the first driving device. The flat arm is bounded by the rotation connection point. The two ends are respectively the balance arm section and the lifting arm section; the trolley is movably connected to the lifting arm section of the flat arm through the second driving device, and the trolley moves along the lifting arm section of the flat arm under the driving of the second driving device. Reciprocating linear motion; the hanging object assembly includes a steel cable, a third driving device and a hook. The steel cable is set at the lower end of the trolley and is associated with the trolley through the third driving device. The hook is connected to the lower end of the steel cable and is controlled by the third driving device. The steel cable is taken up or paid out to control the vertical lifting and lowering movement of the hook;

其还包括吊物辅助支持组件、安全监测组件、PC机、单片机;It also includes hoisting auxiliary support components, safety monitoring components, PCs, and microcontrollers;

吊物辅助支持组件包括摄像头A、摄像头B、摄像头C及毫米波雷达;摄像头A安装在塔身上,其用于获取塔身周边的地面及空中的视野,摄像头B安装在起重臂段下端,其用于获取起重臂段的下部区域的视野,摄像头C安装在小车下端,其用于获取吊钩及吊钩正下方的视野;毫米波雷达安装在起重臂段下端,其用于获取起重臂段的下部区域的障碍物分布情况;The hoisting auxiliary support components include camera A, camera B, camera C and millimeter wave radar; camera A is installed on the tower body, which is used to obtain ground and air views around the tower body; camera B is installed on the lower end of the boom section. It is used to obtain the field of view of the lower area of the boom section. The camera C is installed at the lower end of the trolley, which is used to obtain the field of view of the hook and directly below the hook. The millimeter wave radar is installed at the lower end of the boom section, which is used to obtain the view. The distribution of obstacles in the lower area of the boom section;

安全监测组件包括激光测距模块、平臂变形检测模块、塔身倾斜检测模块及风力检测模块;两个激光测距模块分别安装在平臂起重臂段相对的两侧壁上,两个激光测距模块的光线射出方向均平行于起重臂段并向起重臂段末端延伸,其用于检测起重臂段的转动路径上是否存在阻挡物;平臂变形检测模块安装在起重臂段下端,其用于检测起重臂段的弯曲变形程度;塔身倾斜检测模块安装在塔身上,其用于检测塔身的弯曲变形程度;风力检测模块安装在塔身和/或平臂上,其用于检测风力等级;The safety monitoring components include a laser ranging module, a flat arm deformation detection module, a tower tilt detection module and a wind detection module; two laser ranging modules are installed on the opposite side walls of the flat arm crane arm section. The light emitting direction of the ranging module is parallel to the boom section and extends to the end of the boom section. It is used to detect whether there are obstacles on the rotation path of the boom section; the flat arm deformation detection module is installed on the boom The lower end of the section is used to detect the degree of bending deformation of the boom section; the tower body tilt detection module is installed on the tower body, which is used to detect the degree of bending deformation of the tower body; the wind force detection module is installed on the tower body and/or the flat arm , which is used to detect wind level;

PC机分别与摄像头A、摄像头B、摄像头C、毫米波雷达通信连接,其用于对摄像头A、摄像头B、摄像头C获取的图像及毫米波雷达获取的雷达数据进行可视化展示;The PC is connected to camera A, camera B, camera C, and millimeter-wave radar respectively, and is used to visually display the images acquired by camera A, camera B, and camera C and the radar data acquired by the millimeter-wave radar;

单片机的信号输入端分别与激光测距模块、平臂变形检测模块、塔身倾斜检测模块、风力检测模块通信连接,单片机的信号输出端分别与第一驱动装置、第二驱动装置、第三驱动装置、PC机通信连接。The signal input end of the single-chip computer is connected to the laser ranging module, the flat arm deformation detection module, the tower tilt detection module, and the wind detection module. The signal output end of the single-chip computer is connected to the first driving device, the second driving device, and the third driving device. Device and PC communication connection.

本发明进一步的技术方案是:PC机还包含快速帧抓取器和图像边缘计算模块;快速帧抓取器分别与摄像头A、摄像头B、摄像头C通信连接,以捕捉摄像头A、摄像头B、摄像头C拍摄的视频图像中的每一帧;图像边缘计算模块与快速帧抓取器通信连接,以对快速帧抓取器提取出的帧画面进行物体轮廓描边处理。A further technical solution of the present invention is: the PC also includes a fast frame grabber and an image edge calculation module; the fast frame grabber is communicated with camera A, camera B, and camera C respectively to capture camera A, camera B, and camera C. For each frame of the video image captured by C; the image edge calculation module communicates with the fast frame grabber to perform object outline stroke processing on the frames extracted by the fast frame grabber.

本发明的技术方案是:一种塔吊控制方法,应用于上述的可视化塔吊控制系统,包括风险处置方法和可视化操控方法;The technical solution of the present invention is: a tower crane control method, applied to the above-mentioned visual tower crane control system, including a risk disposal method and a visual control method;

可视化操控方法如下:The visual manipulation method is as follows:

a、通过摄像头A和摄像头B获取被吊物件周边的地面及空中的视野,通过摄像头C获取吊钩及吊钩正下方的视野,通过毫米波雷达获取被吊物件周边的障碍物分布情况雷达图;a. Obtain the ground and air views around the lifted object through camera A and camera B, obtain the view of the hook and directly below the hook through camera C, and obtain the radar map of the distribution of obstacles around the suspended object through millimeter wave radar. ;

b、摄像头A、摄像头B、摄像头C、毫米波雷达的探测范围均为锥形,所述锥形的顶点即为摄像头A、摄像头B、摄像头C、毫米波雷达的位置所在,所述锥形的中心线与水平面所成夹角即为探测角度;则有,摄像头A的探测角度大于摄像头B的探测角度,摄像头C的探测角度为90°,毫米波雷达的探测角度与摄像头A的探测角度相同;b. The detection ranges of camera A, camera B, camera C, and millimeter wave radar are all cone-shaped. The vertex of the cone is the location of camera A, camera B, camera C, and millimeter wave radar. The cone shape The angle between the center line of and the horizontal plane is the detection angle; then, the detection angle of camera A is greater than the detection angle of camera B, the detection angle of camera C is 90°, the detection angle of millimeter wave radar is the same as the detection angle of camera A same;

c、摄像头A、摄像头B、摄像头C拍摄的图像,以及毫米波雷达获取的雷达图,均在与PC机连接的一台显示器的不同区域实时显示,或在与PC机连接的多台显示器上分别显示;c. The images captured by Camera A, Camera B, and Camera C, as well as the radar images obtained by millimeter-wave radar, are displayed in real time in different areas of a monitor connected to the PC, or on multiple monitors connected to the PC. Display separately;

风险处置方法如下:Risk management methods are as follows:

a、通过风力检测模块实时检测塔吊周边的风力等级,检测结果通过单片机传递至PC机;当风力大于6级时,由PC机发出预警,提示操作人员停止塔吊操作;当风力大于8级时,由单片机直接控制塔吊的第一驱动装置、第二驱动装置、第三驱动装置停止运行,使塔吊停止运行;a. Use the wind detection module to detect the wind level around the tower crane in real time, and the detection results are transmitted to the PC through the microcontroller; when the wind strength is greater than level 6, the PC will issue an early warning, prompting the operator to stop operating the tower crane; when the wind strength is greater than level 8, The single-chip microcomputer directly controls the first driving device, the second driving device and the third driving device of the tower crane to stop running, so that the tower crane stops running;

b、通过塔身倾斜检测模块实时检测塔身的倾角,定义倾角为塔身与竖直平面所成夹角,设为r,塔吊空载的情况下,r为0°;当r的范围为-0.2°<r<0.2°时,塔身的倾角在安全值范围内;当r≥1°或r≤-1°时,由单片机直接控制塔吊的第一驱动装置、第二驱动装置、第三驱动装置停止运行,使塔吊停止运行;当-1°<r≤-0.2°或0.2°≤r<1°时,PC机发出预警,提示操作人员停止塔吊操作;b. Use the tower tilt detection module to detect the inclination angle of the tower in real time. Define the inclination angle as the angle between the tower body and the vertical plane, and set it to r. When the tower crane is unloaded, r is 0°; when the range of r is When -0.2°<r<0.2°, the inclination angle of the tower is within the safe value range; when r≥1° or r≤-1°, the single-chip computer directly controls the first driving device, the second driving device, and the third driving device of the tower crane. The three drive devices stop running, causing the tower crane to stop running; when -1°<r≤-0.2° or 0.2°≤r<1°, the PC will issue an early warning to prompt the operator to stop the tower crane operation;

c、通过平臂变形检测模块实时检测起重臂段的弯曲变形程度,平臂变形检测模块为压力传感器,所述压力传感器安装在起重臂段中部下端,距离起重臂段末端距离为起重臂段全长的1/3,通过单片机设置警报阈值和停机阈值,警报阈值小于停机阈值;当塔吊空载时,起重臂段仅在自身重量下产生向下的弯曲变形,当塔吊吊运物件时,起重臂段在被吊物件及自身重量的共同作用下弯曲变形程度增大,对压力传感器施加的压力也相应增大,压力传感器的检测数值也相应增大;c. Detect the bending deformation degree of the boom section in real time through the flat arm deformation detection module. The flat arm deformation detection module is a pressure sensor. The pressure sensor is installed at the lower end of the middle part of the boom section. The distance from the end of the boom section is 1/3 of the total length of the boom section. The alarm threshold and shutdown threshold are set through the microcontroller. The alarm threshold is smaller than the shutdown threshold. When the tower crane is unloaded, the boom section only bends downward under its own weight. When the tower crane is When transporting objects, the bending deformation of the lifting arm section increases under the combined action of the lifted object and its own weight, and the pressure exerted on the pressure sensor also increases accordingly, and the detection value of the pressure sensor also increases accordingly;

设定压力传感器的检测数值为F,当0<F<a时,起重臂段弯曲变形程度在安全范围内,当a≤F<b时,PC机发出预警,提醒操作人员停止塔吊操作,当F≥b时,由单片机同时执行以下几项控制:1、控制第一驱动装置停止运行,使平臂停止转动;2、控制第二驱动装置动作,将小车移动至远离起重臂段末端的极限位置,以减轻起重臂段的弯曲变形程度;3、控制第三驱动装置动作,使吊钩下放,将被吊物件放回地面上;Set the detection value of the pressure sensor to F. When 0<F<a, the bending deformation of the boom section is within the safe range. When a≤F<b, the PC will issue an early warning to remind the operator to stop the tower crane operation. When F≥b, the microcontroller performs the following controls at the same time: 1. Control the first driving device to stop running, so that the flat arm stops rotating; 2. Control the action of the second driving device to move the car away from the end of the boom section limit position to reduce the bending deformation of the boom section; 3. Control the action of the third driving device to lower the hook and return the lifted object to the ground;

d、通过激光测距模块检测起重臂段的转动路径上是否存在阻挡物,设定激光测距模块距离起重臂段末端的固有距离为s,激光测距模块的测距值为h,当h>s时,表示起重臂段的转动路径上不存在阻挡物,当h≤s时,表示起重臂段的转动路径上存在阻挡物;d. Use the laser ranging module to detect whether there are obstacles on the rotation path of the boom section. Set the inherent distance between the laser ranging module and the end of the boom section to s, and the ranging value of the laser ranging module to h. When h>s, it means that there are no obstacles on the rotation path of the boom section; when h≤s, it means that there are obstacles on the rotation path of the boom section;

两个激光测距模块同时启动测距,以同一时间点测距值相对较小的激光测距模块作为判断基准;当h>s+p时,表示起重臂段在转动过程中不会撞到障碍物;当h≤s+p时,表示起重臂段在转动过程中存在撞上障碍物的风险,则由单片机控制第一驱动装置停止运行,使平臂停止转动;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 the basis for judgment; when h>s+p, it means that the boom section will not collide during rotation. to the obstacle; when h ≤ s + p, it means that the boom section has the risk of hitting the obstacle during rotation, and the single-chip microcomputer controls the first driving device to stop running, causing the flat arm to stop rotating;

p为安全距离,取值范围为0.1~0.5m。p is the safety distance, ranging from 0.1 to 0.5m.

本发明再进一步的技术方案是:快速帧抓取器抓取摄像头A、摄像头B、摄像头C拍摄图像中的帧画面,再通过图像边缘计算模块对帧画面进行物体轮廓描边处理,最后通过PC机的显示器呈现物体轮廓描边处理后的画面;所述的物体轮廓描边处理以画面中物体的形状或画面中的颜色阈值变化作为约束条件。A further technical solution of the present invention is: the fast frame grabber captures the frames in the images captured by camera A, camera B, and camera C, and then performs object outline stroke processing on the frames through the image edge calculation module, and finally uses the PC The display of the computer presents the picture after the object outline stroke processing; the object outline stroke processing uses the shape of the object in the picture or the color threshold change in the picture as a constraint.

本发明与现有技术相比具有如下优点:Compared with the prior art, the present invention has the following advantages:

1、通过毫米波雷达和多个摄像头的组合,获取吊塔周边的视野及障碍物分布情况,操作人员基于摄像头获取的图像和毫米波雷达获取的雷达图,即可准确定位物料和把握作业现场环境信息,进而在地面操控室内就可以对塔吊进行远程精准高效的操控,降低了操作人员的工作强度。1. Through the combination of millimeter wave radar and multiple cameras, the field of view and the distribution of obstacles around the pendant are obtained. Based on the image obtained by the camera and the radar map obtained by the millimeter wave radar, the operator can accurately locate the material and grasp the work site. Environmental information can be used to control the tower crane remotely and accurately in the ground control room, reducing the operator's work intensity.

2、通过安全监测组件对塔吊的运行状态信息及外部环境信息进行监测,并建立了一整套完善的风险预警及处置流程,帮助操作人员实时了解到塔吊的状态信息,确保塔吊安全工作,极大提高了塔吊作业的安全性。2. Monitor the operating status information and external environment information of the tower crane through the safety monitoring component, and establish a complete set of risk warning and disposal processes to help operators understand the status information of the tower crane in real time and ensure the safe operation of the tower crane, which greatly Improves the safety of tower crane operations.

以下结合图和实施例对本发明作进一步描述。The present invention will be further described below in conjunction with the figures and examples.

附图说明Description of the drawings

图1为本发明的结构示意图;Figure 1 is a schematic structural diagram of the present invention;

图2为本发明各部件的通信连接关系示意图;Figure 2 is a schematic diagram of the communication connection relationship of various components of the present invention;

图3为现有的塔吊结构示意图。Figure 3 is a schematic diagram of the existing tower crane structure.

图例说明:塔基11;塔身12;平臂13;平衡臂段131;起重臂段132;第一驱动装置14;小车15;第二驱动装置16;钢缆171;第三驱动装置172;吊钩173;摄像头A21;摄像头B22;摄像头C23;毫米波雷达24;激光测距模块31;平臂变形检测模块32;塔身倾斜检测模块33;风力检测模块34;PC机4;快速帧抓取器41;图像边缘计算模块42;单片机5。Legend: tower base 11; tower body 12; flat arm 13; balance arm section 131; lifting arm section 132; first driving device 14; trolley 15; second driving device 16; steel cable 171; third driving device 172 ; Hook 173; Camera A21; Camera B22; Camera C23; Millimeter wave radar 24; Laser ranging module 31; Flat arm deformation detection module 32; Tower tilt detection module 33; Wind detection module 34; PC 4; Fast frame Grabber 41; image edge calculation module 42; microcontroller 5.

具体实施方式Detailed ways

实施例1:Example 1:

如图1-2所示,可视化塔吊控制系统,包括塔吊、吊物辅助支持组件、安全监测组件、PC机、单片机。As shown in Figure 1-2, the visual tower crane control system includes the tower crane, auxiliary support components for hoisting objects, safety monitoring components, PCs, and microcontrollers.

塔吊包括塔基11、塔身12、平臂13、第一驱动装置14、小车15、第二驱动装置16和吊物组件。塔基11固定安装在地面上。塔身12固定连接在塔基11上端。平臂13通过第一驱动装置14可转动的连接在塔身12上端,平臂13在第一驱动装置14的驱动下做水平面上的转动,平臂13以转动连接点为界,两端分别为平衡臂段131和起重臂段132。小车15通过第二驱动装置16活动连接在平臂13的起重臂段132上,小车15在第二驱动装置16的驱动下沿着平臂13的起重臂段132做往复直线运动。吊物组件包括钢缆171、第三驱动装置172和吊钩173,钢缆171设置在小车15下端,并通过第三驱动装置172与小车15关联,吊钩173连接在钢缆171下端,通过第三驱动装置172控制钢缆171的收线或放线,进而控制吊钩173做竖直升降移动。The tower crane includes a tower base 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 base 11 is fixedly installed on the ground. The tower body 12 is fixedly connected to the upper end of the tower base 11 . The flat arm 13 is rotatably connected to the upper end of the tower body 12 through the first driving device 14. The flat arm 13 is driven by the first driving device 14 to rotate on the horizontal plane. The flat arm 13 is bounded by the rotation connection point, and the two ends are respectively They are the balance arm section 131 and the lifting arm section 132. The trolley 15 is movably connected to the boom section 132 of the flat arm 13 through the second driving device 16 . The trolley 15 makes a reciprocating linear motion along the boom section 132 of the flat arm 13 driven by the second driving device 16 . The hanging object assembly includes a steel cable 171, a third driving device 172 and a 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 hook 173 is connected to the lower end of the steel cable 171 and passes through The third driving device 172 controls the take-up or pay-out of the steel cable 171, and then controls the vertical lifting movement of the hook 173.

吊物辅助支持组件包括摄像头A21、摄像头B22、摄像头C23及毫米波雷达24。摄像头A21安装在塔身12上,其用于获取塔身12周边的地面及空中的视野,摄像头B22安装在起重臂段132下端,其用于获取起重臂段132的下部区域的视野,摄像头C23安装在小车15下端,其用于获取吊钩173及吊钩173正下方的视野。毫米波雷达24安装在起重臂段132下端,其用于获取起重臂段132的下部区域的障碍物分布情况。The auxiliary support components for hoisting objects include camera A21, camera B22, camera C23 and millimeter wave radar 24. Camera A21 is installed on the tower body 12, which is used to obtain the field of view of the ground and the air around the tower body 12. Camera B22 is installed on the lower end of the boom section 132, which is used to obtain the field of view of the lower area of the boom section 132. The camera C23 is installed at the lower end of the trolley 15, and is used to obtain the view of the hook 173 and directly below the hook 173. The millimeter wave radar 24 is installed at the lower end of the boom section 132 and is used to obtain the distribution of obstacles in the lower area of the boom section 132 .

安全监测组件包括激光测距模块31、平臂变形检测模块32、塔身倾斜检测模块33及风力检测模块34。两个激光测距模块31分别安装在平臂13起重臂段132相对的两侧壁上,两个激光测距模块31的光线射出方向均平行于起重臂段132并向起重臂段132末端延伸,其用于检测起重臂段132的转动路径上是否存在阻挡物。平臂变形检测模块32安装在起重臂段132下端,其用于检测起重臂段132的弯曲变形程度。塔身倾斜检测模块33安装在塔身12上,其用于检测塔身12的弯曲变形程度。风力检测模块34安装在塔身12上,其用于检测风力等级。The safety monitoring component includes a laser ranging module 31, a flat arm deformation detection module 32, a tower tilt detection module 33 and a wind detection module 34. The two laser ranging modules 31 are respectively installed on the opposite side walls of the boom section 132 of the flat arm 13. The light emitting directions of the two laser ranging modules 31 are parallel to the boom section 132 and toward the boom section. 132 extends at the end and is used to detect whether there is an obstacle on the rotation path of the boom section 132 . The flat arm deformation detection module 32 is installed at the lower end of the boom section 132 and is used to detect the degree of bending deformation of the boom section 132 . The tower body tilt detection module 33 is installed on the tower body 12 and is used to detect the bending deformation degree of the tower body 12 . The wind detection module 34 is installed on the tower body 12 and is used to detect the wind level.

PC机4分别与摄像头A21、摄像头B22、摄像头C23、毫米波雷达24通信连接,其用于对摄像头A21、摄像头B22、摄像头C23获取的图像及毫米波雷达24获取的雷达数据进行可视化展示。The PC 4 is connected to the camera A21, the camera B22, the camera C23, and the millimeter wave radar 24 respectively, and is used to visually display the images acquired by the camera A21, the camera B22, and the camera C23 and the radar data acquired by the millimeter wave radar 24.

单片机5的信号输入端分别与激光测距模块31、平臂变形检测模块32、塔身倾斜检测模块33、风力检测模块34通信连接,单片机5的信号输出端分别与第一驱动装置14、第二驱动装置16、第三驱动装置172、PC机4通信连接。单片机5与第一驱动装置14、第二驱动装置16、第三驱动装置172通信连接用于控制塔吊的运行状态,单片机5与PC机4通信连接用于将安全监测组件获取的监测数据在PC机4上可视化展示。The signal input end of the single-chip microcomputer 5 is communicatively connected to the laser ranging module 31, the flat arm deformation detection module 32, the tower tilt detection module 33, and the wind detection module 34. The signal output end of the single-chip microcomputer 5 is respectively connected to the first driving device 14 and the first driving device 14. The second driving device 16, the third driving device 172 and the PC 4 are connected through communication. The single-chip microcomputer 5 is communicatively connected to the first driving device 14, the second driving device 16, and the third driving device 172 for controlling the operating status of the tower crane. The single-chip microcomputer 5 is communicatively connected to the PC 4 for storing the monitoring data obtained by the safety monitoring component on the PC. Visual display on machine 4.

优选,摄像头A21、摄像头B22、摄像头C23均选用内置4G模组的网络摄像头。Preferably, camera A21, camera B22, and camera C23 all use web cameras with built-in 4G modules.

优选,PC机4包含快速帧抓取器41和图像边缘计算模块42,PC机4通过快速帧抓取器41分别与摄像头A21、摄像头B22、摄像头C23通信连接,以捕捉摄像头A21、摄像头B22、摄像头C23拍摄的视频图像中的每一帧。图像边缘计算模块42与快速帧抓取器41通信连接,以对快速帧抓取器41提取出的帧画面进行物体轮廓描边处理。Preferably, the PC 4 includes a fast frame grabber 41 and an image edge calculation module 42. The PC 4 communicates with the camera A21, the camera B22, and the camera C23 through the fast frame grabber 41, respectively, to capture the camera A21, the camera B22, and the camera C23. Each frame in the video image captured by camera C23. The image edge calculation module 42 is communicatively connected with the fast frame grabber 41 to perform object outline stroke processing on the frames extracted by the fast frame grabber 41 .

优选,快速帧抓取器41的型号为IMPERX_VCE-CLEX01,图像边缘计算模块42的型号为NVIDIA JETSON TX2。Preferably, the model of the fast frame grabber 41 is IMPERX_VCE-CLEX01, and the model of the image edge computing module 42 is NVIDIA JETSON TX2.

优选,单片机5的型号为stm32f103zet6。Preferably, the model of the microcontroller 5 is stm32f103zet6.

一种塔吊控制方法,应用于上述的可视化塔吊控制系统,包括风险处置方法和可视化操控方法。A tower crane control method, applied to the above-mentioned visual tower crane control system, includes a risk treatment method and a visual control method.

可视化操控方法如下:The visual manipulation method is as follows:

a、通过摄像头A21和摄像头B22获取被吊物件周边的地面及空中的视野,通过摄像头C23获取吊钩173及吊钩173正下方的视野,通过毫米波雷达获取被吊物件周边的障碍物分布情况雷达图。a. Obtain the ground and air views around the lifted object through camera A21 and camera B22, obtain the view of hook 173 and directly below the hook 173 through camera C23, and obtain the distribution of obstacles around the suspended object through millimeter wave radar. Radar chart.

b、摄像头A21、摄像头B22、摄像头C23、毫米波雷达24的探测范围均为锥形,所述锥形的顶点即为摄像头A21、摄像头B22、摄像头C23、毫米波雷达24的位置所在,所述锥形的中心线与水平面所成夹角即为探测角度;则有,摄像头A21的探测角度大于摄像头B22的探测角度,摄像头C23的探测角度为90°,毫米波雷达24的探测角度与摄像头A21的探测角度相同。b. The detection ranges of camera A21, camera B22, camera C23, and millimeter wave radar 24 are all cone-shaped, and the apex of the cone is the location of camera A21, camera B22, camera C23, and millimeter wave radar 24. The angle between the center line of the cone and the horizontal plane is the detection angle; then, the detection angle of camera A21 is greater than the detection angle of camera B22, the detection angle of camera C23 is 90°, and the detection angle of millimeter wave radar 24 is the same as that of camera A21 The detection angle is the same.

c、摄像头A21、摄像头B22、摄像头C23拍摄的图像,以及毫米波雷达24获取的雷达图,均在与PC机4连接的一台显示器的不同区域实时显示,或在与PC机4连接的多台显示器上分别显示。c. The images captured by camera A21, camera B22, and camera C23, as well as the radar map obtained by millimeter wave radar 24, are displayed in real time on different areas of a monitor connected to PC 4, or on multiple monitors connected to PC 4. displayed separately on each monitor.

风险处置方法如下:Risk management methods are as follows:

a、通过风力检测模块34实时检测塔吊周边的风力等级,检测结果通过单片机5传递至PC机4;当风力大于6级时,由PC机4发出预警,提示操作人员停止塔吊操作;当风力大于8级时,由单片机5直接控制塔吊的第一驱动装置14、第二驱动装置16、第三驱动装置172停止运行,使塔吊停止运行。a. The wind power level around the tower crane is detected in real time through the wind detection module 34, and the detection result is transmitted to the PC 4 through the single-chip microcomputer 5; when the wind power is greater than level 6, the PC 4 issues an early warning to prompt the operator to stop the tower crane operation; when the wind power is greater than At level 8, the single-chip microcomputer 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, causing the tower crane to stop running.

b、通过塔身倾斜检测模块33实时检测塔身12的倾角,定义倾角为塔身12与竖直平面所成夹角,设为r,塔吊空载(即吊钩173上未吊装物件)的情况下,r为0°;当r的范围为-0.2°<r<0.2°时,塔身12的倾角在安全值范围内;当r≥1°或r≤-1°时,由单片机5直接控制塔吊的第一驱动装置14、第二驱动装置16、第三驱动装置172停止运行,使塔吊停止运行;当-1°<r≤-0.2°或0.2°≤r<1°时,PC机4发出预警(在与PC机相连接的显示器上显示报警信息),提示操作人员停止塔吊操作。b. The inclination angle of the tower body 12 is detected in real time through the tower body inclination detection module 33. The inclination angle is defined as the angle between the tower body 12 and the vertical plane, and is set to r. The tower crane is unloaded (that is, no objects are hoisted on the hook 173). In this case, r is 0°; when the range of r is -0.2°<r<0.2°, the inclination angle of the tower 12 is within the safe value range; when r≥1° or r≤-1°, the single-chip microcomputer 5 Directly control 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 -1°<r≤-0.2° or 0.2°≤r<1°, PC Machine 4 issues an early warning (alarm information is displayed on the monitor connected to the PC), prompting the operator to stop the tower crane operation.

c、通过平臂变形检测模块32实时检测起重臂段132的弯曲变形程度,平臂变形检测模块32为压力传感器,所述压力传感器安装在起重臂段132中部下端,距离起重臂段132末端距离为起重臂段132全长的1/3,通过单片机5设置警报阈值和停机阈值,警报阈值小于停机阈值;当塔吊空载时,起重臂段132仅在自身重量下产生向下的弯曲变形,当塔吊吊运物件时,起重臂段132在被吊物件及自身重量的共同作用下弯曲变形程度增大,对压力传感器施加的压力也相应增大,压力传感器的检测数值也相应增大;c. Detect the bending deformation degree of the boom section 132 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 boom section 132, away from the boom section. The end distance of 132 is 1/3 of the total length of the boom section 132. The alarm threshold and shutdown threshold are set through the single-chip microcomputer 5. The alarm threshold is smaller than the shutdown threshold. When the tower crane is unloaded, the boom section 132 only generates directional force under its own weight. When the tower crane lifts an object, the bending deformation of the boom section 132 increases under the combined action of the lifted object and its own weight, and the pressure exerted on the pressure sensor also increases accordingly, and the detection value of the pressure sensor also increased accordingly;

设定压力传感器的检测数值为F,当0<F<a时,起重臂段弯曲变形程度在安全范围内,当a≤F<b时,PC机发出预警,提醒操作人员停止塔吊操作,当F≥b时,由单片机同时执行以下几项控制:1、控制第一驱动装置14停止运行,使平臂13停止转动;2、控制第二驱动装置16动作,将小车15移动至远离起重臂段132末端的极限位置,以减轻起重臂段132的弯曲变形程度;3、控制第三驱动装置172动作,使吊钩173下放,将被吊物件放回地面上;Set the detection value of the pressure sensor to F. When 0<F<a, the bending deformation of the boom section is within the safe range. When a≤F<b, the PC will issue an early warning to remind the operator to stop the tower crane operation. When F≥b, the microcontroller executes the following controls at the same time: 1. Control the first driving device 14 to stop running, so that the flat arm 13 stops rotating; 2. Control the action of the second driving device 16 to move the trolley 15 away from the starting point. The extreme position of the end of the boom section 132 to reduce the bending deformation of the boom section 132; 3. Control the action of the third driving device 172 to lower the hook 173 and put the hoisted object back on the ground;

当塔吊吊运其允许起吊的最大重量的物件时,压力传感器受到的压力为停机阈值;当塔吊吊运其允许起吊的最大重量80%的物件时,压力传感器受到的压力为报警阈值。When the tower crane lifts objects with the maximum weight it is allowed to lift, the pressure on the pressure sensor is the shutdown threshold; when the tower crane lifts 80% of the maximum weight it is allowed to lift, the pressure on the pressure sensor is the alarm threshold.

d、通过激光测距模块31检测起重臂段132的转动路径上是否存在阻挡物,设定激光测距模块31距离起重臂段132末端的固有距离为s,激光测距模块31的测距值为h,当h>s时,表示起重臂段132的转动路径上不存在阻挡物,当h≤s时,表示起重臂段132的转动路径上存在阻挡物;d. Use the laser ranging module 31 to detect whether there are obstacles on the rotation path of the boom section 132. Set the inherent distance between the laser ranging module 31 and the end of the boom section 132 to s. The measurement of the laser ranging module 31 The distance value is h. When h>s, it means that there are no obstacles on the rotation path of the boom section 132. When h≤s, it means that there are obstacles on the rotation path of the boom section 132;

两个激光测距模块31同时启动测距,以同一时间点测距值相对较小的激光测距模块31作为判断基准;当h>s+p时,表示起重臂段132在转动过程中不会撞到障碍物;当h≤s+p时,表示起重臂段132在转动过程中存在撞上障碍物的风险,则由单片机5控制第一驱动装置14停止运行,使平臂13停止转动;p为安全距离,取值范围为0.1~0.5m。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 the judgment standard; when h>s+p, it means that the boom section 132 is in the process of rotation will not hit obstacles; when h≤s+p, it means that there is a risk of hitting obstacles during the rotation of the boom section 132, then the single-chip microcomputer 5 controls the first driving device 14 to stop running, so that the flat arm 13 Stop rotating; p is the safety distance, ranging from 0.1 to 0.5m.

优选,快速帧抓取器41抓取摄像头A21、摄像头B22、摄像头C23拍摄图像中的帧画面后,再通过图像边缘计算模块42对帧画面进行物体轮廓描边处理,最后通过PC机的显示器呈现物体轮廓描边处理后的画面;所述的物体轮廓描边处理以画面中物体的形状或画面中的颜色阈值变化作为约束条件。Preferably, after the fast frame grabber 41 grabs the frames in the image captured by the camera A21, the camera B22, and the camera C23, it then performs object outline stroke processing on the frame through the image edge calculation module 42, and finally presents it through the monitor of the PC. The picture after object contour stroke processing; the object contour stroke processing uses the shape of the object in the 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 suspended object component; the tower footing is fixedly arranged on the ground; the tower body is fixedly connected to the upper end of the tower foundation; the flat arm is rotatably connected to the upper end of the tower body through a first driving device, the flat arm rotates on a horizontal plane under the driving of the first driving device, the flat arm is bounded by a rotation connection point, and the two ends of the flat arm are respectively a balance arm section and a crane arm section; the trolley is movably connected to the lifting arm 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 lifting arm section of the flat arm; the lifting assembly comprises a steel cable, a third driving device and a lifting hook, wherein 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 at the lower end of the steel cable, and the wire winding or the wire releasing of the steel cable is controlled through the third driving device so as to control the lifting hook to vertically lift;
the intelligent crane is characterized by further comprising a crane auxiliary supporting component, a safety monitoring component, a PC and a singlechip;
the suspended object auxiliary support component 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 vision around the tower body, the camera B is arranged at the lower end of the crane arm section and used for acquiring the vision 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 vision of the lifting hook and the position right below the lifting hook; the millimeter wave radar is arranged at the lower end of the crane arm section and is 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 boom section of the flat arm, the light emission directions of the two laser ranging modules are parallel to the boom section and extend towards the tail end of the boom section, and the two laser ranging modules are used for detecting whether a barrier exists on the rotating path of the boom section; the flat arm deformation detection module is arranged at the lower end of the lifting arm section and is used for detecting the bending deformation degree of the lifting arm section; the tower body inclination detection module is arranged on the tower body and is used for detecting the bending deformation degree of the tower body; the wind power detection module is arranged on the tower body 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 singlechip is respectively 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, and the signal output end of the singlechip is respectively in communication connection with the first driving device, the second driving device, the third driving device and the PC.
2. The visual tower crane control system of claim 1, wherein: the PC also comprises a fast frame grabber and an image edge calculation module; the quick frame grabber is respectively connected with the camera A, the camera B and the camera C in a communication way so as to capture each frame in video images shot by the camera A, the camera B and the camera C; the image edge calculation module is in communication connection with the rapid frame grabber so as to carry out object contour tracing on the frame pictures extracted by the rapid frame grabber.
3. A tower crane control method applied to the visual tower crane control system of claim 2, comprising a risk handling method and a visual control method;
the visual control method comprises the following steps:
a. the method comprises the steps of obtaining the ground and aerial view of the periphery of a hung object through a camera A and a camera B, obtaining the view of a lifting hook and the view under the lifting hook through a camera C, and obtaining a radar map of the obstacle distribution condition of the periphery of the hung object 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 the 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 the cone and the horizontal plane is the detection angle; if 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. the camera A, the camera B and the camera C shoot images, and the radar image 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 treatment method is as follows:
a. the wind power level around the tower crane is detected in real time through the wind power detection module, and the detection result is transmitted to the PC through the singlechip; when the wind power is greater than 6 levels, a PC machine gives an early warning to prompt an operator to stop the operation of the tower crane; when the wind power is greater than 8 levels, the single chip microcomputer directly controls the first driving device, the second driving device and the third driving device of the tower crane to stop running, so that the tower crane stops running;
b. the inclination angle of the tower body is detected in real time through the tower body inclination detection module, the inclination angle is defined as an included angle formed by the tower body and a vertical plane, and is set as r, and the r is 0 degree under the condition that the tower crane is empty; when r is within the range of-0.2 degrees and less than 0.2 degrees, the inclination angle of the tower body is within the range of a safety value; when r is more than or equal to 1 degrees or r is less than or equal to-1 degrees, the first driving device, the second driving device and the third driving device of the tower crane are directly controlled by the singlechip to stop running, so that the tower crane stops running; when r is less than or equal to-1 degrees and less than or equal to-0.2 degrees or r is less than or equal to 0.2 degrees and less than or equal to 1 degrees, the PC sends out early warning to prompt operators to stop the operation of the tower crane;
c. the bending deformation degree of the crane arm section is detected in real time through a flat arm deformation detection module, the flat arm deformation detection module is a pressure sensor, the pressure sensor is arranged at the lower end of the middle part of the crane arm section, the distance from the tail end of the crane arm section is 1/3 of the total length of the crane arm section, an alarm threshold value and a stop threshold value are set through a singlechip, and the alarm threshold value is smaller than the stop threshold value; when the tower crane is empty, the crane arm section 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 is increased under the combined action of the lifted object and the self weight, 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 crane arm section is in a safety range, when a is less than or equal to F and less than b, sending out early warning by the PC machine, reminding an operator to stop the operation of the tower crane, and when F is more than or equal to b, simultaneously executing the following control by the singlechip: 1. controlling the first driving device to stop running, so that the flat arm stops rotating; 2. controlling the second driving device to act, and moving the trolley to a limit position far away from the tail end of the crane arm section so as to lighten the bending deformation degree of the crane arm section; 3. controlling the third driving device to act, so that the lifting hook is lowered, and the hung object is put back on the ground;
d. detecting whether a blocking object exists on a rotating path of the crane arm section through a laser ranging module, setting the inherent distance between the laser ranging module and the tail end of the crane arm section as s, setting the ranging value of the laser ranging module as h, indicating that the blocking object does not exist on the rotating path of the crane arm section when h is more than s, and indicating that the blocking object exists on the rotating path of the crane arm section when h is less than or equal to s;
the two laser ranging modules start ranging at the same time, and the laser ranging module with a relatively smaller ranging value at the same time point is used as a judging reference; when h is more than s+p, the crane arm section does not collide with an obstacle in the rotating process; when h is less than or equal to s+p, indicating that the boom section has risk of bumping into an obstacle in the rotating process, controlling the first driving device to stop running by the singlechip to stop rotating the flat arm;
p is a safe distance, and the value range is 0.1-0.5 m.
4. A tower crane control method as claimed in claim 3, wherein: capturing frame pictures in images by a camera A, a camera B and a camera C by a rapid frame grabber, carrying out object contour tracing on the frame pictures by an image edge calculation module, and finally presenting the pictures subjected to the object contour tracing by a display of a PC; the object contour 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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