CN115535857A

CN115535857A - System and method for safely lifting steel ladle by crane

Info

Publication number: CN115535857A
Application number: CN202211179184.3A
Authority: CN
Inventors: 马晓标; 郑君; 张文英; 陈志刚; 张玉华; 刘必胜
Original assignee: Maanshan Iron and Steel Co Ltd
Current assignee: Maanshan Iron and Steel Co Ltd
Priority date: 2022-09-27
Filing date: 2022-09-27
Publication date: 2022-12-30

Abstract

The invention discloses a system and a method for safely lifting a steel ladle by a crane, belonging to the field of crane equipment control systems. The hoisting method of the invention collects XYZ three-dimensional space positions of crane cart, trolley and hoisting height and XY two-dimensional plane position of ground buggy ladle, and compares and confirms; and a shooting tracking technology is adopted in a trunnion area of the ladle lifted by the plate hook, and the accurate position of the hanging ladle is determined through feature extraction and picture judgment analysis. The invention establishes data communication between the crane and the ground cross-car, realizes integrated centralized control on the car and the ground, and effectively ensures safe and reliable ladle lifting operation.

Description

System and method for safely hoisting steel ladle by crane

Technical Field

The invention belongs to the field of crane equipment control systems, and particularly relates to a wireless data transmission and automation control technology, in particular to a system and a method for safely lifting a steel ladle by a crane.

Background

In metallurgical steel-making production, a liquid casting crane undertakes the lifting and logistics work of liquid molten metal, wherein the ladle lifting operation relates to a plurality of important parameters such as ladle weight, cart position, trolley position, hoisting height, ground cross-car position and the like, and the gantry plate hook of the crane can be reliably hung on a ladle trunnion. As long as a certain parameter has deviation, major safety accidents such as deformation of a plate hook and a slide hook, inclination of a steel ladle, overflow of molten iron and the like can occur.

At the present stage, the ladle lifting operation mainly depends on the command of ground leaders, and is assisted by the selection of factory building marks and personal experience judgment of a driver. However, when the light is insufficient and the steam dust is large on site, the leaders and drivers cannot accurately judge the important parameters, the working efficiency is directly influenced, and the potential safety hazard is large.

Taking a ladle reversing pit for hoisting a hot metal ladle as an example, after the hot metal is discharged, a straddle carrier is driven to a charging bay for hoisting operation, and the position of the straddle carrier is stopped to different positions according to personal operation habits on the ground, so that a unified standard is not formed, the hoisting operation can be completed by adjusting the positions of plate hooks for many times, and the efficiency is low; when the steel ladle is hoisted, due to the difference of personal literacy and responsibility of ground leaders, the accurate hanging of the gantry plate hook into the trunnion of the steel ladle cannot be confirmed every time when the steel ladle is hoisted under command, and great potential safety hazard exists.

Through retrieval, publication No. CN106144900A discloses a device and a method for automatically acquiring the state of a lifting hook of a lifting point in a driving cab, a camera is installed at a ground ladle, video collected by the camera is transmitted to a crane driver through a wireless video transmission analog FM modulation technology, and the video is wirelessly transmitted by adopting analog FM modulation. But the problems of longer time delay, poor anti-interference capability and the like exist in the picture, so that misoperation is easily caused; meanwhile, the position of the crossing vehicle is not fixed, and the camera acquires a fixed picture with deviation, so that the operation of a driver is influenced.

Disclosure of Invention

1. Problems to be solved

Aiming at the condition that the safety of the current ladle lifting operation is still insufficient, the invention provides a system and a method for safely lifting a ladle by a crane, and particularly, the lifting method collects XYZ three-dimensional space positions of a cart, a trolley and a hoisting height of the crane and XY two-dimensional plane positions of a ground ladle car, and compares and confirms the XYZ three-dimensional space positions; and (3) adopting a camera tracking technology in the trunnion area of the plate hook hoisting ladle, and determining the accurate position of the hoisting ladle through feature extraction and picture judgment analysis. The invention establishes data communication between the crane and the ground cross-car, realizes integrated centralized control on the car and the ground, and effectively ensures safe and reliable ladle lifting operation.

2. Technical scheme

In order to solve the above problems, the present invention adopts the following technical solutions.

The invention relates to a safe hoisting ladle system of a crane, which comprises a crane cart position acquisition module, a trolley position acquisition module, a hoisting height acquisition module, a plate hook hoisting ladle trunnion information acquisition module and a ground cross-car position acquisition module, wherein the crane cart position acquisition module, the plate hook hoisting ladle trunnion information acquisition module and the ground cross-car position acquisition module are used for on-vehicle data acquisition and ground data acquisition, an on-vehicle data acquisition PLC (programmable logic controller) is used for acquiring cart position, trolley position and hoisting height data, the ground data acquisition PLC is used for acquiring ground plate hook hoisting ladle trunnion judgment results, cross-car position and ladle weight data, the ground data is subjected to data exchange with an on-vehicle wireless communication module through a wireless communication module, and a man-machine interface is installed in a cab and used for displaying the positions of mechanisms, ladle weight in a ladle reversing pit and the plate hook hoisting ladle trunnion judgment results and performing on-vehicle and ground integrated centralized control.

Furthermore, the crane cart position acquisition module comprises a Gray bus arranged at a cart walking platform railing and an antenna box arranged on a vehicle body end beam, wherein the induction area of the antenna box and the Gray bus are on the same horizontal line; a terminal box and a power supply box are further mounted on the cart walking platform handrail, one end of the antenna box is connected with a decoder, gray codes generated by the Gray bus are unlocked and induced by the decoder and converted into distances, the distances are converted into required protocols by a protocol converter and connected with a switch, the required protocols are communicated with a data acquisition PLC on a cart through the switch, and the accurate position of a cart body is read; the switch is connected with an on-vehicle wireless communication module for data exchange.

Furthermore, the trolley position acquisition module comprises a laser positioning inspection device arranged at the end of the trolley track on one side, a reflecting plate is additionally arranged right above the trolley track, and a laser projection area is positioned in the center of the reflecting plate; the laser positioning inspection device is communicated with the onboard data acquisition PLC through Ethernet.

Furthermore, the winch height acquisition module comprises an AB bidirectional output encoder arranged on a five-gear shaft of the speed reducer and is connected with a counter module of the onboard data acquisition PLC through a signal shielding wire.

Furthermore, the plate hook hoisting ladle trunnion information acquisition module comprises following cameras arranged on two sides of the reladling pit railing, and the plate hook is designated as a tracking target and is positioned in the center of an acquisition picture; the method comprises the steps of collecting pictures along with a camera and sending the pictures into a computer classifier for training, enabling the pictures to have the detection capability on a target through training learning of positive samples and negative samples, marking the pictures which are easy to classify into errors into correct classes, putting the pictures into a sample library for training and self-adapting, processing the pictures to obtain image data, and outputting the result to an I/O (input/output) module of a ground data acquisition PLC (programmable logic controller).

Furthermore, the ground straddle carrier position acquisition module comprises a laser positioning inspection device arranged at the end position of the straddle carrier track and a reflecting plate correspondingly arranged on the straddle carrier, the laser positioning inspection device is connected with a ground data acquisition PLC through an Ethernet switch, and a ladle dumping pit weighing system is used for connecting and communicating with the ground data acquisition PLC through the Ethernet switch to acquire the weight of the ladle; a voice alarm system is arranged beside the tank transfer pit and is connected with a ground data acquisition PLC; the port of the Ethernet switch is connected with a wireless communication module.

The method for safely lifting the steel ladle by the crane adopts the steel ladle system safely lifted by the crane, and comprises the following steps:

s1, marking a 1# reladling pit position H1, a 2# reladling pit position H2, an obstacle H3, a trolley lower pit position H4, a winch lower pit lifting steel ladle height H5, a lifting steel ladle cross-car position H6 and a lifting steel ladle trolley position H7 in a PLC program, establishing data communication between a crane and the reladling pit when an X # reladling pit of the X # crane is sent out by a ground leading line, popping the crane and the position, height and weight data of the reladling pit by a human-computer interface, and acquiring the weight of the steel ladle in the reladling pit; when the weight of the steel ladle is larger than the hoisting load weight of the crane, an on-board voice alarm system of a cab alarms and starts to remind an operator to prohibit hoisting operation; when the weight of the ladle is less than or equal to the hoisting weight of the crane, an operator carries out cart alignment, the cart reaches a specified ladle reversing pit, the trolley mechanism is operated to a trolley pit position H4, and the winch reaches a winch pit lifting ladle height H5;

s2, when a ladle lifting command is sent by a leading line, a human-computer interface acquires a position H6 where a ladle is lifted over a straddle carrier and a position H7 where a ladle lifting trolley is lifted, triggers the following cameras at two sides of a ladle pouring pit to acquire images, and analyzes, judges and outputs a result to an I/O (input/output) module of a ground data acquisition PLC (programmable logic controller); an operator operates the trolley to a position H7, if the position of the lifted ladle passing through the straddle carrier is deviated from the calibration position H6, the operator can be reminded of adjusting the straddle carrier to the position H6 by voice, or the system can automatically calculate the deviation distance and remind the operator of adjusting the position of the trolley by voice; the difference value between the position of the trolley and the position of the cross trolley is 0, an operator starts the hoisting to ascend, stops the hoisting to ascend at the moment of stress of the plate hook, confirms the verticality of the steel wire rope, and continues to ascend to the set height when the condition is met; during the period, if the image is collected, the plate hook shakes to send out voice prompt, the collected plate hook and the steel ladle trunnion are dislocated and separated to send out voice alarm, and the winch is forbidden to continue to rise.

Furthermore, in the S1, the operator performs cart alignment in a system-assisted positioning mode, which specifically includes: an operator normally operates the crane to move towards the X # reladling pit direction, confirms the position of the crane in front, operates the trolley and the winch to avoid the barrier H3, displays the current position of the trolley and calibrates the reladling pit position in the data acquisition PLC program on the trolley through the human-computer interface, and can quickly and accurately position according to the comparison of the two position data; after the cart reaches the designated ladle reversing pit, an operator marks the position of the trolley pit and the height of the hoisting ladle to be hoisted, and operates the trolley mechanism to the position H4 of the trolley pit and the height H5 of the hoisting ladle to be hoisted.

Furthermore, in S1, the operator performs cart alignment in a system index positioning mode, which specifically includes: the man-machine interface is provided with a system index positioning button, the index positioning button is touched, the cart is positioned in an index positioning mode, an operator operates the crane to run towards the direction of the X # reladling pit, when the position of the cart and the hoisting height are detected to be in an H3 area of an obstacle, a voice prompt is sent out at a position 1 away from the obstacle, the speed is reduced at a position 2, and the cart stops at a position 3; obtaining an absolute value Y1 obtained by subtracting the position of the front crane from the current crane position, obtaining Y2 by adding the width of the crane to the Y1, sending voice prompt when the Y2 is less than a set distance 4, setting the speed reduction at the distance 2, and stopping at the distance 3, if the front crane runs in the direction of the current crane, sending the voice prompt at the distance 5, setting the speed reduction at the distance 6, and stopping at the distance 7; subtracting the numerical value of the position of the tank dumping pit calibrated in the PLC program from the current position of the cart to obtain an absolute value Y3, and sending out corresponding voice prompt when the value of Y3 is a set distance 8, a set distance 9 and a set distance 10; and after the cart reaches the specified ladle reversing pit, prompting by a system index, placing the position of the trolley at the position H4 of a trolley pit, after the position of the trolley reaches H4, prompting by the system that the winch descends, placing the trolley at the height H5 of a hoisting ladle at the position H5 of the hoisting pit, and after the winch reaches H5, prompting by the system that alignment is completed and waiting for hoisting the ladle.

Furthermore, in the S1, the operator performs cart alignment in an automatic system positioning mode, which specifically includes: the man-machine interface is provided with a system automatic positioning button, the system automatic positioning button is touched, the cart is positioned in an automatic positioning mode, the system automatically detects whether the position of the cart and the height of the winch are in an obstacle H3 area, the position of the cart and the height of the winch are automatically adjusted to be in a safe area, the position of a front crane is read, the cart automatically runs and positions, an absolute value Y3 is obtained by subtracting the numerical value of the position of the tank dumping pit according to the current position of the cart and the internal calibration of an onboard data acquisition PLC program, the moment is adjusted by combining a cart brake, the Y3 value is smaller than a set distance 11, the rotating speed set value of a frequency converter is continuously adjusted until the in-place speed set value of the cart is 0, and the cart stops; after the cart reaches the designated tank dumping pit, the system automatically adjusts the position of the trolley to H4 and adjusts the winch height to H5; the operation level of the linkage table is higher than that of the automatic positioning of the system, and the linkage table acts and the automatic positioning function fails.

3. Advantageous effects

Compared with the prior art, the invention has the beneficial effects that:

(1) The method for safely lifting the ladle by the crane acquires the XYZ three-dimensional space position of the crane and the XY two-dimensional plane position of the ground ladle car for calculation and comparison, and the crane effectively avoids obstacles and adjacent cranes in the advancing process; the plate hook hoisting ladle trunnion area ensures accurate position of the hoisting ladle through the camera shooting tracking technology, the characteristic extraction and the picture judgment analysis, establishes the data communication between the crane and the ground cross-car, realizes the integrated centralized control on the car and the ground, and effectively ensures the safe and reliable hoisting operation of the ladle.

(2) According to the method for safely hoisting the steel ladle by the crane, the hoisting position of the crane is more accurate by adopting the position comparison technology, and whether the plate hook is accurately hung on the trunnion of the steel ladle or not is effectively confirmed by adopting the camera tracking technology; three modes of system auxiliary positioning, system index positioning and system automatic positioning are set in the actual operation process of the system, so that the practical application is wider; the data can be collected according to the actual perfection of the site, and the program operation can be modified, so that the data can better meet the site requirements, and the method has high popularization and application values.

Drawings

FIG. 1 is a schematic structural diagram of a cart position acquisition unit according to the present invention;

FIG. 2 is a schematic structural view of a trolley position acquisition unit and a winch height acquisition unit in the invention;

fig. 3 is a schematic structural diagram of a ground location information acquisition unit according to the present invention.

In the figure:

11. a Gray bus; 12. an antenna box; 13. a terminal box; 14. a power supply box; 15. a decoder; 16. a protocol converter; 17. a switch; 18. an onboard data acquisition PLC; 19. an on-board wireless communication module; 21. a laser positioning inspection device; 22. a reflective plate; 23. AB bidirectional output encoder; 24. a signal shielding line; 25. a human-machine interface; 26. an on-board voice alarm system; 31. a tank dumping pit; 32. a following camera; 33. a plate hook; 34. a computer; 35. a laser positioning inspection device; 36. an Ethernet switch; 37. a ground data acquisition PLC; 38. a reladling pit weighing system; 39. a voice alarm system; 40. a wireless communication module.

Detailed Description

The invention is further described with reference to specific examples.

Example 1

As shown in fig. 1-3, the system for safely lifting a steel ladle by a crane according to the present embodiment includes a crane cart position acquisition module, a trolley position acquisition module, a hoisting height acquisition module, a plate hook lifting steel ladle trunnion information acquisition module and a ground cross-car position acquisition module, which are respectively used for performing on-vehicle data acquisition and ground data acquisition, an on-vehicle data acquisition PLC18 is used for acquiring cart position, trolley position and hoisting height data, a ground data acquisition PLC37 is used for acquiring ground plate hook lifting steel ladle trunnion determination results, cross-car position and steel ladle weight data, the ground data exchanges data with an on-vehicle wireless communication module 19 through a wireless communication module 40, and a human-computer interface 25 is installed in a cab and is used for displaying positions of mechanisms, steel ladle weight in a ladle dumping pit, plate hook lifting steel ladle trunnion determination results, and integrated centralized control of the on-vehicle and the ground. In the embodiment, XYZ three-dimensional space positions of a crane cart, a crane trolley and a winch are compared with XY two-dimensional plane positions of a ground transition vehicle for confirmation; a shooting tracking technology is adopted in a trunnion area of a ladle lifted by a plate hook, and an analysis and judgment drawing result is transmitted to a ground data acquisition PLC37 through feature extraction, so that the accuracy of lifting the ladle by a crane is effectively ensured.

Specifically, as shown in fig. 1, the crane cart position acquisition module comprises a gray bus 11 arranged at a cart walking rail and an antenna box 12 arranged at the middle position of a car body end beam, wherein the sensing area of the antenna box 12 and the gray bus 11 are on the same horizontal line, and the distance between the sensing area and the gray bus 11 is adjusted to ensure the sensing effect; a terminal box 13 and a power supply box 14 are further installed on the cart walking platform handrail, one end of an antenna box 12 is connected with a decoder 15, a Gray code generated by unlocking an induction Gray bus 11 through the decoder 15 is converted into a distance, the distance is converted into a required protocol through a protocol converter 16 and is connected with an exchanger 17, the required protocol is communicated with a cart data acquisition PLC18 through the exchanger 17, and the accurate position of a cart body is read; the switch 17 is connected with an on-board wireless communication module 19 for data exchange.

As shown in fig. 2, the trolley position acquisition module comprises a laser positioning inspection device 21 installed at the end of a trolley track on one side, a reflecting plate 22 is installed above the trolley track, and a laser projection area is located at the center of the reflecting plate 22; the pulse method is used for ranging, the laser positioning and checking device 21 sends out a laser reflecting plate 22 to reflect, and then the laser reflecting plate is received by the laser positioning and checking device 21, and half of the product of the light speed and the round trip time is the measured distance; the laser positioning inspection device 21 is communicated with the on-vehicle data acquisition PLC18 through Ethernet, and a GSD file is installed in the laser positioning inspection device 21 to directly read the position data of the laser positioning inspection device 21.

Specifically, the hoisting height acquisition module comprises a bidirectional output encoder 23 arranged on a five-gear shaft of the speed reducer, X pulse signals are sent out by rotating for one circle, and the five-gear shaft of the speed reducer is synchronous with the rotating speed of the winding drum; the high-speed counter records that the bidirectional output encoder 23 sends out a pulse signal n when rotating, namely the winding action height is n/x the circumference of a winding drum; the hoisting is judged to be lifted or lowered by adopting bidirectional output, data accumulation is automatically carried out, and the bidirectional output encoder 23 is periodically counted by means of a shift-switching trial limiting system.

A man-machine interface 25 is installed in a cab, is connected with an on-vehicle data acquisition PLC18 through an RJ45 port of a switch 17 and is used for displaying the positions of all mechanisms, the weight of a steel ladle in a ladle reversing pit, the position of a cross-car and the conditions of plate hooks and trunnions on two sides of the steel ladle through computer vision judgment; the voice alarm system 26 is equipped with voice prompt and voice alarm. The port of the switch 17 is connected with an on-vehicle wireless communication module 19, and the on-vehicle wireless communication module and the ground data acquisition PLC37 carry out data communication and integrated control on the on-vehicle and the ground.

As shown in fig. 3, the plate hook hoisting ladle trunnion information acquisition module comprises following cameras 32 arranged at two sides of a railing of a ladle reversing pit 31, a locking tracking technology is adopted, a plate hook 33 is designated as a tracking target and is positioned in the center of an acquisition picture, and when the target distance changes, the tracking target can be automatically adjusted to automatically zoom and focus, so that the purpose of high-definition acquisition is achieved; classifying the collected pictures, extracting the characteristics, sending the pictures into a computer 34 classifier for training, enabling the pictures to have the detection capability on the target through training and learning of positive samples and negative samples, marking the pictures which are easy to classify and have errors with correct classes, putting the pictures into a sample library for training and self-adapting, processing the pictures to obtain image data, and outputting the result to an I/O module of a ground data acquisition PLC 37.

As shown in fig. 2, the ground straddle carrier position acquisition and the trolley position acquisition are the same, the ground straddle carrier position acquisition module comprises a laser positioning inspection device 35 installed at the end position of the straddle carrier rail and a reflecting plate correspondingly installed on the straddle carrier, the distance between the two spans is short, the data acquisition precision of the laser positioning inspection device 35 meets the requirement, the laser positioning inspection device 35 is connected with a ground data acquisition PLC37 through an ethernet switch 36, a GSD file is installed, and the position data is directly read; a ladle inverting pit weighing system 38 is connected with and communicated with a ground data acquisition PLC37 through an Ethernet switch 36 to obtain the weight of the ladle; a voice alarm system 39 is arranged beside the tank dumping pit 31 and is connected with a ground data acquisition PLC 37; the port of the Ethernet exchanger 36 is connected with a wireless communication module 40, and the same network segment, different IP addresses and integrated control on the vehicle and the ground are arranged between the crane and the tank dumping pit.

s1, marking a 1# reladling pit position H1, a 2# reladling pit position H2, an obstacle H3, a trolley lower pit position H4, a winch lower pit lifting steel ladle height H5, a lifting steel ladle crossing straddle position H6 and a lifting steel ladle trolley position H7 in a vehicle data acquisition PLC18 program, establishing data communication between a crane and the reladling pit 31 when a ground is led to send out an X # reladling pit of the X # crane, popping the crane and the position, height and weight data of the reladling pit 31 by a human-computer interface 25, and acquiring the weight of a steel ladle in the reladling pit 31;

when the weight of the steel ladle is larger than the hoisting load weight of the crane, the voice alarm system 26 on the vehicle of the cab alarms and starts to remind the operator to prohibit the hoisting operation;

when ladle weight is less than or equal to hoist suspended load weight, operating personnel carries out the cart counterpoint, and is specifically optional:

the method comprises a first mode and a system auxiliary positioning mode, wherein an operator normally operates a crane to run in the X # reladling pit direction, confirms the position of the crane in front, operates a trolley and a winch to avoid an obstacle H3, displays the current position of the trolley and calibrates the reladling pit position (such as the 1# reladling pit H1) in a data acquisition PLC18 program on the trolley on a human-computer interface 25, and can quickly and accurately position according to the comparison of two position data; after the cart reaches the designated ladle reversing pit, an operator marks the position of the trolley pit and the height of the hoisting ladle to be hoisted, and operates the trolley mechanism to the position H4 of the trolley pit and the height H5 of the hoisting ladle to be hoisted.

A second mode, system index positioning, wherein the human-computer interface 25 is provided with a system index positioning button and a system automatic positioning button, the index positioning button is touched, the cart is positioned in the index positioning mode, an operator operates the crane to move towards the direction of the X # reladling pit, when the position of the cart and the hoisting height are detected to be in an H3 area of the obstacle, a voice prompt is sent out at a position which is 1 away from the obstacle, the speed is reduced at a position which is 2 away from the obstacle, and the cart is stopped at a position which is 3 away from the obstacle; obtaining an absolute value Y1 obtained by subtracting the position of the front crane from the current crane position, obtaining Y2 by adding the width of the crane to the Y1, sending voice prompt when the Y2 is less than a set distance 4, setting the speed reduction at the distance 2, and stopping at the distance 3, if the front crane runs in the direction of the current crane, sending the voice prompt at the distance 5, setting the speed reduction at the distance 6, and stopping at the distance 7; subtracting the numerical value of the position of the tank dumping pit calibrated in the PLC program from the current position of the cart to obtain an absolute value Y3, and sending out corresponding voice prompts when the value of Y3 is a set distance 8, a set distance 9 and a set distance 10; and after the cart reaches the designated ladle reversing pit, prompting by a system index, placing the trolley position in a trolley pit-falling position H4, after the trolley position reaches H4, prompting by the system that the winch descends, placing the trolley pit-falling position in the winch pit-falling position to lift the ladle by the height H5, and after the winch reaches H5, prompting by the system that alignment is completed, and waiting for lifting the ladle.

The system automatically positions, touches an automatic positioning button, the cart is positioned in an automatic positioning mode, the system automatically detects whether the cart position and the winch height are in an obstacle H3 area, automatically adjusts the cart position and the winch height to be in a safe area, reads the position of a front crane, automatically operates and positions the cart, subtracts the numerical value of the position of the tank dumping pit calibrated in the PLC18 program according to the current position of the cart and the data on the cart to obtain an absolute value Y3, adjusts the moment by combining a cart brake, reduces the speed by the value Y3 being smaller than a set distance 11, and continuously adjusts the rotating speed set value of a frequency converter until the set speed set value of the cart in place is 0; after the cart reaches the designated tank dumping pit, the system automatically adjusts the position of the trolley to H4 and adjusts the winch height to H5; the operation level of the linkage table is higher than that of the automatic positioning of the system, and the linkage table acts and the automatic positioning function fails. The specific distance value from the set distance 1 to the set distance 11 is determined according to the practical application requirement, that is, the corresponding operation is performed at the corresponding position, which is not described herein again.

S2, when a hoisting ladle command is sent by a leader, the human-computer interface 25 acquires a position H6 where a hoisting ladle passes through a straddle carrier and a position H7 where a ladle trolley is hoisted, triggers the following cameras 32 at two sides of the ladle reversing pit 31 to acquire images, and analyzes, judges and outputs a result to an I/O module of a ground data acquisition PLC 37; an operator operates the trolley to a position H7, if the position of the lifted ladle passing through the straddle carrier is deviated from the calibration position H6, the operator can be reminded of adjusting the straddle carrier to the position H6 by voice, or the system can automatically calculate the deviation distance and remind the operator of adjusting the position of the trolley by voice; the difference value between the position of the trolley and the position of the straddle carrier is 0, the operator starts the hoisting to ascend, stops the hoisting to ascend at the moment when the plate hook 33 is stressed, confirms the verticality of the steel wire rope, and continues to ascend to the set height when the condition is met; during the period, if the collected image is that the plate hook 33 shakes to send out voice prompt, the collected plate hook 33 is staggered with the trunnion of the ladle and is separated from the trunnion to send out voice alarm, and the winch is forbidden to continue rising.

In the embodiment, the crane cart, the trolley and the winch XYZ three-dimensional space position are collected, compared and analyzed with the ground transition vehicle XY two-dimensional plane position, and a calculation model is established, so that the crane can effectively avoid obstacles and adjacent vehicles during operation, and meanwhile, the steel ladle hoisting positioning is more accurate; secondly, a shooting tracking technology is adopted in a trunnion area of the plate hook hoisting ladle to classify collected pictures, characteristics are extracted, a target detection function is realized through training and learning of positive samples and negative samples, and easily classified wrong pictures are marked with correct categories and placed in a sample library for self-adaptation, so that image data can be acquired more accurately. In the embodiment, the data communication between the crane and the ground cross vehicle is established, the communication is arranged in the same network segment and different IP addresses are used, and the integrated centralized control of the crane on the vehicle and the ground is realized; three modes of system auxiliary positioning, system index positioning, system automatic positioning and the like are set in the actual operation process, and the operation level of the linkage table is prioritized, so that the application is wider and safer; and a man-machine interface design is adopted, man-machine conversation is realized, the distance from the barrier is respectively provided with the protection functions of voice prompt, speed reduction, parking and the like, and the power supply can be directly cut off under the dangerous conditions that a similar plate hook is not hung in a steel ladle trunnion and the like, so that the action is forbidden, and the application is safer.

The examples described herein are merely illustrative of the preferred embodiments of the present invention and do not limit the spirit and scope of the invention, and various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the design concept of the present invention should fall within the protection scope of the present invention.

Claims

1. A hoist lifts by crane ladle system safely which characterized in that: the system comprises a crane cart position acquisition module, a trolley position acquisition module, a hoisting height acquisition module, a plate hook hoisting steel ladle trunnion information acquisition module and a ground cross-car position acquisition module, and is used for carrying out data acquisition and ground data acquisition on a crane, an on-car data acquisition PLC (18) is used for acquiring the position of the cart, the position of the trolley and the hoisting height data, a ground data acquisition PLC (37) is used for acquiring the judgment result of the plate hook hoisting steel ladle trunnion, the cross-car position and the weight data of the steel ladle, the ground data is subjected to data exchange with an on-car wireless communication module (19) through a wireless communication module (40), a man-machine interface (25) is installed in a cab and is used for displaying the position of each mechanism, the weight of the steel ladle in a tank dumping pit, the judgment result of the plate hook hoisting steel ladle, and the on-car and ground integrated control of the trunnion.

2. A crane safety hoisting ladle system according to claim 1, wherein: the crane cart position acquisition module comprises a Gray bus (11) arranged at a cart walking platform rail and an antenna box (12) arranged on a car body end beam, wherein the induction area of the antenna box (12) and the Gray bus (11) are on the same horizontal line; a terminal box (13) and a power supply box (14) are further installed on the cart walking handrail, one end of the antenna box (12) is connected with a decoder (15), gray codes generated by unlocking and sensing a Gray bus (11) through the decoder (15) are converted into distances, the distances are converted into required protocols through a protocol converter (16) to be connected with an exchanger (17), and the required protocols are communicated with a data acquisition PLC (18) on the cart through the exchanger (17) to read the accurate position of a cart body; the exchanger (17) is connected with an on-board wireless communication module (19) for data exchange.

3. A crane safety hoisting ladle system according to claim 1, wherein: the trolley position acquisition module comprises a laser positioning inspection device (21) arranged at the end of a trolley track on one side, a reflecting plate (22) is additionally arranged right above the trolley track, and a laser projection area is positioned in the center of the reflecting plate (22); the laser positioning inspection device (21) is communicated with the on-board data acquisition PLC (18) by adopting Ethernet.

4. A crane safety hoisting ladle system according to claim 1, wherein: the winch height acquisition module comprises an AB bidirectional output encoder (23) arranged on a five-gear shaft of the speed reducer and is connected with a counter module of the vehicle data acquisition PLC (18) through a signal shielding wire (24).

5. A crane safety hoisting ladle system according to claim 1, wherein: the plate hook hoisting ladle trunnion information acquisition module comprises following cameras (32) arranged on two sides of a railing of a ladle reversing pit (31), and a plate hook (33) is designated as a tracking target and is positioned in the center of an acquisition picture; the following camera (32) collects pictures and sends the pictures to a computer (34) classifier for training, the pictures are enabled to have the detection capability on the target through the training and learning of positive samples and negative samples, the pictures which are easy to classify and have errors are marked with the correct classes, the pictures are placed into a sample library for training and self-adaptation, image data are obtained through processing, and the result is output to an I/O module of a ground data collection PLC (37).

6. A crane safety hoisting ladle system according to claim 1, wherein: the ground cross-vehicle position acquisition module comprises a laser positioning inspection device (35) installed at the end position of a cross-vehicle track and a reflecting plate correspondingly installed on the cross-vehicle, the laser positioning inspection device (35) is connected with a ground data acquisition PLC (37) through an Ethernet switch (36), and a reladling pit weighing system (38) is connected with the ground data acquisition PLC (37) through the Ethernet switch (36) for communication to acquire the weight of a steel ladle; a voice alarm system (39) is arranged beside the reladling pit (31) and is connected with a ground data acquisition PLC (37); the port of the Ethernet switch (36) is connected with a wireless communication module (40).

7. A method for safely lifting a ladle by a crane is characterized by comprising the following steps: safely hoisting a ladle system by using the crane according to any one of claims 1 to 6, the process is as follows:

s1, marking a 1# reladling pit position H1, a 2# reladling pit position H2, an obstacle H3, a trolley reladling pit position H4, a hoisting reladling pit hoisting ladle height H5, a hoisting ladle cross-vehicle position H6 and a hoisting ladle trolley position H7 in a vehicle data acquisition PLC (18) program, establishing data communication between a crane and the reladling pit (31) when a ground is led to send out the X # reladling pit below the X # crane, popping up the crane and the position, height and weight data of the reladling pit (31) by a human-machine interface (25), and acquiring the weight of a ladle in the reladling pit (31); when the weight of the steel ladle is larger than the hoisting load weight of the crane, an on-board voice alarm system (26) of the cab alarms and starts to remind an operator to prohibit hoisting operation; when the weight of the ladle is less than or equal to the hoisting load weight of the crane, an operator carries out cart alignment, the cart reaches a designated ladle reversing pit (31), a trolley mechanism is operated to a trolley pit position H4, and the winch reaches a winch pit lifting ladle height H5;

s2, when a command for lifting the steel ladle is sent by a leading party, a human-computer interface (25) acquires the position H6 of the lifting steel ladle passing through a straddle carrier and the position H7 of a lifting steel ladle trolley, triggers the following cameras (32) at two sides of a ladle reversing pit (31) to acquire images, analyzes and judges the output result and sends the result to an I/O module of a ground data acquisition PLC (37); an operator operates the trolley to a position H7, if the position of the lifted ladle passing through the straddle carrier is deviated from the calibration position H6, the operator can be reminded of adjusting the straddle carrier to the position H6 by voice, or the system can automatically calculate the deviation distance and remind the operator of adjusting the position of the trolley by voice; the difference value between the position of the trolley and the position of the cross trolley is 0, an operator starts the hoisting to ascend, stops the hoisting to ascend at the moment of stress of the plate hook (33), confirms the verticality of the steel wire rope, and continues to ascend to the set height when the condition is met; during the period, if the collected plate hook (33) shakes to send out voice prompt, the collected plate hook (33) and the steel ladle trunnion are dislocated and separated to send out voice alarm, and the winch is forbidden to continue to rise.

8. A method of safely lifting a ladle with a crane according to claim 7, wherein: in S1, an operator performs cart alignment by adopting a system auxiliary positioning mode, and the method specifically comprises the following steps: an operator normally operates the crane to move towards the X # reladling pit direction, confirms the position of the crane in front, operates the trolley and the winch to avoid the barrier H3, displays the current position of the cart and calibrates the reladling pit position inside a data acquisition PLC (18) program on the cart through a human-computer interface (25), and can quickly and accurately position according to the comparison of the two position data; after the cart reaches the designated ladle reversing pit, an operator marks the position of the trolley pit and the height of the hoisting ladle to be hoisted, and operates the trolley mechanism to the position H4 of the trolley pit and the height H5 of the hoisting ladle to be hoisted.

9. A method of safely lifting a ladle with a crane according to claim 7, wherein: in the S1, an operator performs cart alignment by adopting a system index positioning mode, and the method specifically comprises the following steps: the human-computer interface (25) is provided with a system index positioning button, the index positioning button is touched, the cart is positioned in an index positioning mode, an operator operates the crane to move towards the direction of the X # reladling pit, when the position of the cart and the winch height are detected to be in an H3 area of the obstacle, a voice prompt is sent out at a position which is 1 away from the obstacle, the speed is reduced at a position which is 2 away from the obstacle, and the cart stops at a position which is 3 away from the obstacle; obtaining an absolute value Y1 obtained by subtracting the position of the front crane from the current crane position, obtaining Y2 by adding the width of the crane to the Y1, sending voice prompt when the Y2 is less than a set distance 4, setting the speed reduction at the distance 2, and stopping at the distance 3, if the front crane runs in the direction of the current crane, sending the voice prompt at the distance 5, setting the speed reduction at the distance 6, and stopping at the distance 7; subtracting the numerical value of the position of the tank dumping pit calibrated in the PLC program from the current position of the cart to obtain an absolute value Y3, and sending out corresponding voice prompts when the value of Y3 is a set distance 8, a set distance 9 and a set distance 10; and after the cart reaches the specified ladle reversing pit, prompting by a system index, placing the position of the trolley at the position H4 of a trolley pit, after the position of the trolley reaches H4, prompting by the system that the winch descends, placing the trolley at the height H5 of a hoisting ladle at the position H5 of the hoisting pit, and after the winch reaches H5, prompting by the system that alignment is completed and waiting for hoisting the ladle.

10. A method of safely lifting a ladle with a crane according to claim 7, wherein: in S1, an operator performs cart alignment by adopting a system automatic positioning mode, and the method specifically comprises the following steps: the man-machine interface (25) is provided with a system automatic positioning button, the automatic positioning button is touched, the cart is positioned in an automatic positioning mode, the system automatically detects whether the cart position and the winch height are in an obstacle H3 area, automatically adjusts the cart position and the winch height in a safety area, reads the position of a front crane, automatically operates and positions the cart, subtracts the numerical value of the position of the tank dumping pit calibrated in the current position of the cart and the data acquisition PLC (18) program on the cart to obtain an absolute value Y3, adjusts the moment by combining a cart brake, reduces the speed by the value Y3 being smaller than a set distance 11, and constantly adjusts the rotating speed set value of the frequency converter until the cart in-place speed set value is 0; after the cart reaches the designated tank dumping pit, the system automatically adjusts the position of the trolley to H4 and adjusts the winch height to H5; the operation level of the linkage table is higher than that of the automatic positioning of the system, and the linkage table acts and the automatic positioning function fails.