CN116199112A - Automatic hoisting system and method for gantry crane - Google Patents

Abstract

The application provides an automatic lifting system and method of gantry crane, the automatic lifting system of gantry crane includes: the device comprises a cart mechanism, a trolley mechanism, a lifting mechanism and a turning plate mechanism; the cart mechanism moves along the construction track direction; the trolley mechanism moves along the length direction of the cross beam; the lifting mechanism drives the lifting appliance to move along the vertical direction; the turning plate mechanism is cooperated with the lifting mechanism to turn over the residue soil box; the control systems of the cart mechanism, the trolley mechanism and the lifting mechanism are all in communication connection with a PLC, absolute value encoders are further arranged in the cart mechanism, the trolley mechanism and the lifting mechanism, the absolute value encoders are configured to acquire three-dimensional position information of the lifting appliance, and the PLC is configured to automatically control movement of the cart mechanism, the trolley mechanism and the lifting appliance according to the three-dimensional position information; the PLC is also preset with an anti-shake program, and the anti-shake program is configured to automatically adjust the speeds of the cart mechanism, the trolley mechanism and the lifting appliance according to the three-dimensional position information; the lifting mechanism also comprises a metal flaw detection device for monitoring the state of the steel wire rope.

Description

Automatic hoisting system and method for gantry crane

Technical Field

The present application relates generally to the field of lifting apparatus technology. More particularly, the present application relates to an automatic gantry crane hoisting system and method.

Background

With the development of Chinese economy, large and medium cities plan and build a plurality of subway projects in order to solve the problem of difficult travel. A large amount of dregs can be generated in the process of tunneling the subway track, and the large amount of dregs are required to be discharged by using a gantry crane mechanism. Currently, controlling the discharge of the muck by means of gantry crane mechanisms is usually performed manually. Due to limited manual operation precision, the slag box is inevitably swayed during loading, unloading and transportation, so that equipment is damaged or slag is spilled.

Therefore, how to provide a safe and stable automatic lifting system and method for the gantry crane is a problem to be solved by those skilled in the art.

Disclosure of Invention

In view of this, the present application provides an automatic lifting system of a gantry crane, which can automatically lift a muck box without manual operation and smoothly unload muck therein to a designated area. The application also provides an automatic hoisting method of the gantry crane.

To achieve the above object, the present application provides an automatic lifting system for a gantry crane, including: the device comprises a cart mechanism, a trolley mechanism, a lifting mechanism and a turning plate mechanism; the cart mechanism comprises a cart main body and a cart running device; the large vehicle body comprises upright posts positioned at two sides of the construction track and a cross beam crossing the construction track, and the upright posts and the cross beam are connected to form a door-shaped structure; the cart running device is arranged below the upright post and is configured to drive the cart body to move along the construction track direction; the trolley mechanism comprises a trolley main body and a trolley running device; the trolley main body is positioned above the cross beam of the large main body; the trolley traveling device is arranged between the trolley main body and the cross beam and is configured to drive the trolley main body to move along the length direction of the cross beam; the lifting mechanism comprises a driving winding drum, a steel wire rope and a lifting appliance; the driving winding drum is arranged on the trolley main body, is connected to the lifting appliance through a steel wire rope and is configured to drive the lifting appliance to move in the vertical direction; the lifting appliance comprises a lifting beam, telescopic arms which can extend and retract along two sides of the lifting beam, a hanging plate positioned below the telescopic arms and a detection switch arranged in the hanging plate, and lifting lugs matched with the hanging plate are arranged on two sides of a muck box to be lifted; the turning plate mechanism comprises a turning plate hook arranged on the trolley main body or the hanging beam, and the turning plate hook is configured to hang at the bottom of the muck box so as to turn over the muck box in cooperation with the lifting mechanism; the control systems of the cart running device, the trolley running device and the driving winding drum are all in communication connection with a Programmable Logic Controller (PLC), absolute value encoders are further arranged in the cart running device, the trolley running device and the driving winding drum, the absolute value encoders are configured to acquire three-dimensional position information of the lifting appliance, and the PLC is configured to automatically control movement of the cart running device, the trolley running device and the driving winding drum according to the three-dimensional position information; the PLC is also preset with an anti-shake program, and the anti-shake program is configured to automatically adjust the speeds of the cart mechanism, the trolley mechanism and the lifting appliance according to the three-dimensional position information; the lifting mechanism also comprises a metal flaw detection device for monitoring the state of the steel wire rope.

Optionally, vibration monitoring sensors are also arranged in the cart running device, the trolley running device and the driving winding drum.

Optionally, a Modbus-TCP industrial communication network is adopted as a main communication network of the gantry crane automatic hoisting system.

Optionally, the gantry crane automatic hoisting system further comprises video monitoring devices arranged around the construction track.

Optionally, the video surveillance device has a face recognition function and a sound system, the video surveillance device being configured to expel non-staff persons by the sound system when they are identified as entering the work area.

Alternatively, the absolute value encoder is a multi-turn absolute value encoder.

Optionally, the lifting appliance is further provided with an electronic scale for weighing the dregs box.

Optionally, the gantry crane automatic hoisting system can be operated automatically, semi-automatically or manually.

Optionally, the metal inspection device is a magnetic inspection device; the magnetic flaw detection device is arranged at a rope outlet position below the driving winding drum and comprises a magnetic memory planning device, a weak magnetic detection device, a follow-up device and a guide rail; the magnetic memory planning device is configured to apply an external magnetic field to the steel wire rope, the weak magnetic detection device is configured to detect the magnetic field near the steel wire rope, and the follow-up device is configured to drive the magnetic memory planning device and the weak magnetic detection device to swing together on the guide rail along with the steel wire rope when the steel wire rope swings due to winding and unwinding.

The application also provides a method for loading and unloading dregs by using the automatic gantry crane hoisting system, which comprises the following steps: s1, a muck box transport vehicle moves to a loading position and establishes communication with an automatic gantry crane hoisting system; s2, the cart main body and the trolley main body move to a loading position; s3, the lifting appliance stretches out of the telescopic arm and descends to a preset height; s4, the lifting appliance retracts the telescopic arm to a preset limit, so that the hanging plate is hung at the lifting lug of the muck box; s5, lifting the lifting appliance to an unloading height; s6, the cart main body and the trolley main body move to an unloading position; s7, hooking the turning plate to the bottom of the dregs box, and simultaneously descending the lifting appliance so as to turn over the dregs box; and S8, resetting.

Compared with the prior art, the automatic hoisting system and method for the gantry crane provided by the application have the following beneficial effects:

(1) The automatic lifting system for the gantry crane is characterized in that absolute value encoders are arranged in the cart running device, the trolley running device and the lifting mechanism driving winding drum, the absolute value encoders can accurately position the gantry crane, the lifting appliance and the muck box in lifting, and the PLC can automatically load and unload and transport the muck box according to positioning information; the whole muck loading, unloading and transporting process does not need manual operation, so that the labor is saved, and meanwhile, the safety accidents caused by manual misoperation are avoided;

(2) The PLC control system is also internally preset with an anti-shake program, and the anti-shake program automatically adjusts the speeds of the cart mechanism, the trolley mechanism and the lifting appliance according to the three-dimensional position information fed back by the absolute value encoder, so that slag soil can not be spilled out due to larger shaking in the loading and unloading and transportation processes of the slag soil box, and the loading and unloading efficiency of the slag soil is indirectly improved; and

(3) The hoisting mechanism further comprises a metal flaw detector for monitoring the state of the steel wire rope, the metal flaw detector is preferably a magnetic flaw detector, the magnetic flaw detector can detect the damage degree of the steel wire rope invisible to naked eyes according to an alternating magnetic field generated when the steel wire rope is scanned, when the steel wire rope is in a problem, the problem is fed back to a worker or a dispatching room in time, and the occurrence of the falling accident of a hoisted object caused by direct fracture of the steel wire rope which is not detected for a long time or is difficult to detect by naked eyes is avoided.

Drawings

In order to more clearly illustrate the technical solutions of the present application, embodiments of the present application will be further illustrated and described according to the following drawings, which are only used to more conveniently and specifically describe embodiments of the present application and are not limiting of the present application.

Fig. 1 is a schematic structural view of a spreader 100 of an automatic gantry crane hoisting system provided according to an example embodiment of the present application;

FIG. 2 is a schematic diagram of a magnetic inspection apparatus 200 provided according to an example embodiment of the present application;

FIG. 3 is a schematic diagram of communication relationship of a control system 300 of an automatic gantry crane lifting system according to an example embodiment of the present application; and

fig. 4 is a flow chart of a gantry crane automatic hoisting method 400 provided according to an example embodiment of the present application.

Detailed Description

The gantry crane is a hoisting device taking a portal girder as a main bearing structural member, a transverse frame of the gantry crane is arranged in the middle of a construction track and can move along the track, and a lifting appliance 100 is hung on a trolley which can move along the transverse beam of the portal girder, so that the lifting appliance 100 can vertically lift and horizontally move so as to transport a lifting object. For the gantry crane, the positioning precision is the basic guarantee of the whole control system, and the positioning precision of the large and small vehicles and the lifting mechanism is less than or equal to + -5 mm, so that the accurate transportation of the lifting object is realized. The automatic hoisting system of the gantry crane provided by the application utilizes the positioning sensor arranged on the large and small vehicles and the hoisting mechanism to accurately measure the three-dimensional position information, and sends the measured result into the PLC, the PLC automatically controls the movement of the large and small vehicles and the hoisting mechanism based on the three-dimensional position information, and the driving system of each mechanism adopts the structural form that the PLC is combined with a frequency converter and a network, so that the PLC can be conveniently and accurately controlled in real time. In a preferred embodiment of the present application, there is provided an automatic lifting system for a gantry crane, comprising: the device comprises a cart mechanism, a trolley mechanism, a lifting mechanism and a turning plate mechanism; the cart mechanism comprises a cart main body and a cart running device; the large vehicle body comprises upright posts positioned at two sides of the construction track and a cross beam crossing the construction track, and the upright posts and the cross beam are connected to form a door-shaped structure; the cart running device is arranged below the upright post and is configured to drive the cart body to move along the construction track direction; the trolley mechanism comprises a trolley main body and a trolley running device; the trolley main body is positioned above the cross beam of the large main body; the trolley traveling device is arranged between the trolley main body and the cross beam and is configured to drive the trolley main body to move along the length direction of the cross beam; the lifting mechanism comprises a driving reel, a steel wire rope and a lifting appliance 100; the driving reel is mounted on the trolley body, the driving reel is connected to the lifting appliance 100 through a steel wire rope, and the driving reel is configured to drive the lifting appliance 100 to move in the vertical direction; the lifting appliance 100 comprises a lifting beam 101, telescopic arms 102 which can extend and retract along two sides of the lifting beam 101, a hanging plate 103 positioned below the telescopic arms 102 and a detection switch 104 arranged in the hanging plate 103, and lifting lugs matched with the hanging plate 103 are arranged on two sides of a muck box to be lifted; the turning plate mechanism comprises a turning plate hook arranged on the trolley main body or the hanging beam 101, wherein the turning plate hook is configured to hang on the bottom of the muck box so as to turn over the muck box in cooperation with the lifting mechanism; the control systems of the cart running device, the trolley running device and the driving winding drum are all in communication connection with a PLC, absolute value encoders are further arranged in the cart running device, the trolley running device and the driving winding drum, the absolute value encoders are configured to acquire three-dimensional position information of the lifting appliance 100, and the PLC is configured to automatically control movement of the cart running device, the trolley running device and the driving winding drum according to the three-dimensional position information. In one specific example, a three-axis coordinate system may be established at the construction track site, absolute value encoders are installed in the cart running gear, the dolly running gear, and the driving reel, respectively, to acquire three-dimensional position information of the spreader 100, and then the PLC moves the spreader 100 from one specific position to another specific position and performs other operations according to an automatic driving program built in. For example, the automated driving program may be configured to perform the following series of operations according to the spreader 100 position, the muck box loading position, and the unloading position: the method includes moving the spreader 100 to a muck box loading position, loading the muck box, moving the spreader 100 with the muck box to an unloading position, unloading muck in the muck box, and moving the muck box back to the muck box loading position. The whole automatic portal crane hoisting system is improved on the basis of the existing portal crane hoisting system, an automatic operation mode and a semi-automatic operation mode are added while the original manual driving operation mode is reserved, and an operator can set the operation mode of the automatic portal crane hoisting system according to actual conditions.

In a preferred embodiment of the present application, the spreader 100 may have a structure as shown in fig. 1. Referring to fig. 1, a lifting appliance 100 includes a lifting beam 101, telescopic arms 102 which can extend and retract along two sides of the lifting beam 101, a hanging plate 103 positioned below the telescopic arms 102, and a detection switch 104 arranged in the hanging plate 103, lifting lugs matched with the hanging plate 103 are arranged on two sides of a muck box, and a driving device connected with a PLC is arranged in the lifting appliance 100. When the lifting task is executed based on an automatic operation mode or a semi-automatic operation mode, the PLC built-in program automatically drives the cart running device and the trolley running device to move the lifting appliance 100 to the position above the dregs box to be loaded, and then lifting operation is executed. When the lifting operation is performed, the lifting appliance 100 extends out of the telescopic arm 102 and is lowered to a preset height, so that the hanging plate 103 of the lifting appliance 100 is aligned with the lifting lug of the muck box, wherein the preset height can be a position preset according to the height of the construction track and the muck box transport vehicle, or can be a position calculated in real time according to the positioning information of the muck box transport vehicle and the positioning information of the lifting appliance 100; after the hanging plate 103 is aligned with the lifting lug, the lifting appliance 100 retracts the telescopic arm 102 to a preset limit, so that the hanging plate 103 is hung at the lifting lug of the muck box; a detection switch 104 is arranged in the hanging plate 103, and the detection switch 104 can be used for detecting whether the hanging plate 103 is matched with the lifting lug or not and can also be used for detecting whether the lifting appliance 100 is in place at the loading position; after the hanging position is completed, the lifting appliance 100 is lifted to an unloading height, and then the cart main body and the trolley main body are moved to the unloading position; when the dregs are unloaded, the turnover plate mechanism drives the dregs box to turn over. In a preferred embodiment of the present application, the flap mechanism comprises a flap hook mounted on the trolley body or the lifting beam 101 and a flap hook drive, which is also connected to and controlled by the PLC. Before the slag soil unloading operation is executed, the first driving turning plate hook is positioned at the bottom of the slag soil box; during the execution of the muck unloading operation, the muck box can be turned over to unload muck by driving the lifting appliance 100 to descend and driving the flap hooks to pull the bottom of the muck box in the opposite direction of muck dumping. In a specific embodiment of the application, the turning plate hook can be a hydraulic transverse moving hook installed on the trolley main body, when the lifting appliance 100 lifts the muck box, the hydraulic transverse moving hook is moved away in advance so as not to collide with the muck box, so that the muck box can be lifted smoothly, lifting can be stopped when the bottom of the muck box is higher than the hydraulic transverse moving hook, then the hydraulic transverse moving hook is moved back to the bottom of the muck box, the hydraulic transverse moving hook is located at the bottom of the muck box by falling the muck box (the bottom of the muck box is provided with a hanging cross bar matched with the hydraulic transverse moving hook), and then the muck box can rotate to pour soil for a twisted point. In an alternative embodiment of the present application, the flap mechanism may be an automatic hydraulic bucket hanging mechanism provided at the bottom of the muck box, which establishes communication with the gantry crane PLC and automatically forces the muck box to turn over in cooperation with the spreader 100 when it is desired to unload muck. In other embodiments, the flap mechanism may be any mechanism known in the art capable of driving the spoil box to turn. In a preferred embodiment of the present application, the spreader 100 is further provided with an electronic scale for weighing the muck box. When the lifting load reaches 90% of the rated lifting weight, the electronic scale can send out a prompting alarm signal, when the lifting load reaches 105% of the rated lifting weight, the lifting mechanism is stopped in a delayed mode, and when the lifting load reaches 110% of the rated lifting weight, the lifting power supply is immediately cut off, so that construction safety is further guaranteed. In an alternative embodiment of the present application, the spreader 100 may not have a telescopic structure, but a conventional rope hook structure, and the hoisting method of this structure is different from the telescopic structure, and the hoisting method will be described in detail in the automatic hoisting method of the gantry crane.

In a preferred embodiment of the present application, the absolute value encoder is a multi-turn absolute value encoder. The measuring range of the multi-turn absolute value encoder is larger, the change is not needed, and the sensor precision can reach 0.1mm. In one embodiment of the present application, the cart mechanism, the trolley mechanism, and the lifting mechanism may be equipped with the same type of positioning system. For example, the cart mechanism, the trolley mechanism, and the lifting mechanism are all positioned using multi-turn absolute encoders. In one embodiment of the present application, the cart mechanism, the trolley mechanism, and the lifting mechanism may be equipped with different types of positioning systems. For example, the cart mechanism and the trolley mechanism are positioned by adopting a multi-turn absolute value encoder, and the lifting mechanism is positioned by adopting a stay wire encoder; or the cart mechanism and the trolley mechanism are positioned by adopting a coding ruler positioning system, and the lifting mechanism is positioned by adopting an absolute value encoder. The code reader of the code scale positioning system reads the code scale in an infrared correlation mode, so that absolute position information is obtained. The encoder scale positioning system does not require a reference point and can calculate the position value without time delay. The position data of the coding rule positioning system is manufactured on the stainless steel coding rule through special coding and perforation processes. The code scale is mounted in parallel on one side of the track, so that a specific position value can be assigned to each position point of the large and small car track. In another exemplary embodiment, the positioning system installed in the cart mechanism, the trolley mechanism, and the lifting mechanism may be a laser ranging sensor. In yet another exemplary embodiment, cart and trolley mechanisms may use a grid Lei Muxian positioning system. It should be understood that the person skilled in the art can select the positioning mode suitable for each dimension of the gantry crane automatic hoisting system according to the actual requirements of the construction site.

In a preferred embodiment of the present application, an anti-roll program is also preset within the PLC, which is configured to automatically adjust the speed of the cart mechanism, trolley mechanism and spreader 100 based on the three-dimensional positional information. When the automatic or semi-automatic operation mode of the automatic hoisting system for the gantry crane is selected, the speeds of the cart, the trolley and the hoisting mechanism are not obtained according to the rated output frequency of the frequency converter, but after the information such as the starting point, the limit area information, the maximum speed acceleration of the running device and the like is automatically or manually set, the set speed of the cart, the trolley or the hoisting mechanism is automatically calculated and output by an anti-shaking program, so that the large shaking amount can not be generated in the hoisting process. In a more preferred embodiment, the anti-roll program also has a control mode with feedforward combined with feedback. In the feedforward combined feedback control mode, a swing angle measuring device is also required to be installed on the lifting mechanism, and the swing angle of the lifting appliance 100 during operation is estimated based on a soft measurement technology. In this mode, the predetermined speed of each running gear is set based on the above start and stop point, limit zone information, maximum speed acceleration of the running gear, etc. by the feed-forward mode, and then the output frequency of the running gear frequency converter is adjusted according to the real-time position, speed and swing angle during the running of the spreader 100 by the feed-back mode, so as to control the actual running speed of the running gear, thereby achieving the purpose of suppressing the swing of the spreader 100. In one embodiment of the present application, the anti-roll program can ensure that the amount of roll of the spreader 100 during operation is less than 30mm and stops the roll within 3 roll cycles after stopping the operation. In a preferred embodiment of the present application, a track planning program is also preset in the PLC, and an obstacle detecting device for identifying the position of an obstacle is also installed in the entire track construction site accordingly. After the lifting appliance 100 is automatically or manually set to the operation start point, if an obstacle exists in the operation path, the track planning program automatically plans a new operation path, and the PLC automatically sets the operation parameters of the lifting appliance 100 according to the new operation path. Further, the track planning procedure and the detection of the obstacle can be performed in real time, the obstacle detection result on the running path can be obtained once at intervals during the automatic running of the lifting appliance 100, if the obstacle exists, the running is suspended and the path is re-planned, so that a more intelligent obstacle avoidance function is realized, and the safety of equipment and constructors is ensured.

In a preferred embodiment of the present application, the hoisting mechanism further comprises a metal inspection device for monitoring the condition of the wire rope. The gantry crane steel wire rope is used as a key component with huge consumption and high danger in hoisting equipment, and various damages such as wire breakage, abrasion, corrosion, fatigue and the like can be generated on the steel wire rope due to complex working conditions and high-load application. Serious consequences can occur if damage builds up until the wire rope breaks. In a preferred embodiment of the present application, the metal inspection device is a magnetic inspection device, for example with reference to fig. 2. Fig. 2 is a schematic structural diagram of a magnetic flaw detection device 200 according to an exemplary embodiment of the present application, and as shown in fig. 2, the magnetic flaw detection device 200 is installed at a rope-out position below a driving reel, and includes a magnetic memory planning device 201, a weak magnetic detection device 202, a follower device 203 and a guide rail 204. The magnetic memory planning device 201 is used for applying an external magnetic field to the steel wire rope so as to form a memory magnetic field near the steel wire rope, the weak magnetic detection device 202 is used for detecting the magnetic field to obtain the loss information of the steel wire rope, and the follow-up device 203 is configured to drive the magnetic memory planning device 201 and the weak magnetic detection device 202 to swing together on the guide rail 204 along with the steel wire rope when the steel wire rope swings due to winding and unwinding so as to prevent the magnetic memory planning device 201 and the weak magnetic detection device 202 from mistakenly touching the steel wire rope. The ferromagnetic material can generate a memory magnetic field related to the physical property of the ferromagnetic material under the action of the magnetic field, and the damage condition of the steel wire rope can be deduced by detecting the magnetic field to obtain the magnetic energy potential difference information of the steel wire rope. The normal steel wire rope can form a stable magnetic field in the magnetic flaw detection range; when the broken part passes through the scanning range, an alternating magnetic field is formed. The damage state of the steel wire rope can be detected by utilizing the magnetic flaw detection principle without disassembling the steel wire rope. When the wire rope has problems, the metal flaw detection device can timely feed the problems back to staff or a dispatching room. In a further preferred embodiment, the metal inspection apparatus further comprises an image recognition apparatus and an AI vision system. The image recognition device acquires an image of the steel wire rope, and the AI vision system monitors whether the steel wire rope is warped, worn and the like based on an image processing method. The magnetic flaw detector 200 is combined with an AI vision system to comprehensively monitor the damage condition of the steel wire rope in real time and send out an alarm related to the damage condition.

In a preferred embodiment of the present application, vibration monitoring sensors are also provided in the cart running gear, the trolley running gear and the drive reel. The vibration monitoring sensor monitors the vibration state of the speed reducer of each driving device, and analyzes whether the current working state of the speed reducer is in good state or not through signal processing. The vibration monitoring sensor ensures that the equipment works well in the whole life cycle working process, and reduces the error rate of human detection.

In a preferred embodiment of the present application, the main communication network of the gantry crane automatic hoisting system is a Modbus-TCP industrial communication network. The system adopts a wired communication technology to complete the interconnection communication of system data, and an optical fiber and a vehicle-mounted base station are respectively arranged at the corresponding position of a construction track and on the intelligent gantry crane to form a wireless and wired communication network. The communication system adopts optical fibers to be connected with the monitoring center, so that stable and reliable transmission of system data is ensured, and real-time performance and rapidity of data transmission are ensured. In a preferred embodiment of the present application, the PLC control system 304 is further coupled to a superordinate MES system 308, and one or more gantry cranes in the field are scheduled and database managed by the superordinate MES system 308. The automatic lifting system of the gantry crane feeds back three-dimensional space coordinates in the operation of the lifting appliance 100 in real time through an encoder, adjusts the operation speed of the lifting appliance 100 in real time through a frequency converter, and feeds back the execution completion result after loading and unloading are completed. Referring to fig. 3, fig. 3 is a schematic diagram of communication relationship of a control system 300 of an automatic gantry crane lifting system according to an exemplary embodiment of the present application. As shown in fig. 3, the cart running gear absolute value encoder 301, the dolly running gear absolute value encoder 302, and the drive reel absolute value encoder 303 acquire three-dimensional position information of the spreader 100 and transmit to the PLC control system 304, and the PLC control system 304 thereby controls the power of the cart running gear frequency converter 305, the dolly running gear frequency converter 306, and the drive reel frequency converter 307. The PLC control system 304 is further connected to an upper MES system 308, and overall regulation and control are achieved through the upper MES system 308. In a preferred embodiment of the present application, the upper MES system 308 is located in a central control room, and its information display system can display various information of the whole gantry crane automatic hoisting system, including but not limited to: hoisting information: lifting height, trolley position, cart position and lifting weight; distance target information: lifting height difference, trolley position difference and trolley position difference; the action and state currently being performed; manual, semi-automatic, full-automatic mode switching; frequency converter information: current, voltage, direction, rotational speed, temperature, fault code; positioning information: position of each target point and electronic limit information; fault information: fault codes and corresponding solutions; the running state of the PLC; communication state of the devices on the network; an operating state of the drive device; controlling the running state of the equipment; analog display of control lines, etc. In a preferred embodiment of the application, the automatic lifting system of the gantry crane further comprises a remote maintenance system, so that the control system has remote fault handling capability, when the equipment is abnormal and field personnel cannot be removed, the equipment can be remotely connected through the 4G internet of things module, and manufacturer technicians can remotely perform fault removal and maintenance, so that overhaul and fault removal time is shortened. In a preferred embodiment of the application, the automatic hoisting system of the gantry crane further comprises a fault query analysis system, and the running state and the fault state of each crane can be queried in real time through the fault query analysis system installed on the industrial personal computer of the central control room, so that management staff can analyze, query and solve faults in time. The fault content can be sent to a background database for storage, so that maintenance personnel can manage and analyze the fault content conveniently.

In a preferred embodiment of the present application, the gantry crane automatic hoisting system further comprises a video monitoring device arranged around the construction track. In order to facilitate the manager to monitor the running state of the equipment in real time, a video monitoring system can be installed in each key area, for example, monitoring points are set in areas such as a pedestrian passageway, a lifting appliance working area, a cart running area and the like, and monitoring data are transmitted to a central control room in a network mode. Further, the video monitoring device arranged near the portal frame working area, especially near the slag pit where slag is temporarily placed, can also be provided with a face recognition function and an acoustic system. When a non-staff person is identified as entering the work area, a warning may be issued by the sound system to expel it.

In a preferred embodiment of the present application, there is also provided a method for loading and unloading slag using the above-described gantry crane automatic lifting system, for example with reference to fig. 4. As shown in fig. 4, the method comprises the steps of: in block 401, the muck box transport vehicle is moved to a loading position and communication is established with the gantry crane automatic hoisting system; at block 402, the cart body and the cart body are moved to a loading position; at block 403, the spreader 100 extends the telescoping arm 102 and lowers to a preset height; at block 404, the spreader 100 retracts the telescoping arm 102 to a preset limit such that the hanging plate 103 is hung at the lifting eye of the muck box; at block 405, the spreader 100 is raised to an unloading height; at block 406, the cart body and the cart body are moved to an unloading position; at block 407, the flap hook is positioned at the bottom of the muck box while the spreader 100 is lowered to turn the muck box over; and at block 408, reset. Optionally, after the spreader 100 is extended out of the telescopic arm 102 and lowered to a preset height at block 404, the spreader 100 may be first left to stand for a period of time to ensure that it is no longer swaying, and the subsequent steps may be performed after the spreader 100 has stabilized. Optionally, the spreader 100 may be raised to the detection position prior to raising the spreader 100 to the unloading height at block 405, and the detection switch 104 may detect whether the spreader 100 is in place and raise the spreader 100 to the unloading height after that. Both the clinker box and the loading position are provided with sensors matched to the detection switch 104, the detection switch 104 being operable to detect whether the hitch plate 103 is engaged with the lifting lug or whether the spreader 100 is in the loading position. In an alternative embodiment of the present application, the spreader 100 may not be provided with a telescopic structure, but a conventional rope hook structure, the hoisting method of which is different from that of the telescopic structure. For example, the method may include: s1, a muck box transport vehicle moves to a loading position and establishes communication with an automatic gantry crane hoisting system; s2, moving the cart to a loading position; s3, moving the trolley to a position about 20cm in front of the dregs box; s4, lowering the lifting appliance 100 to the height of the muck box, so that the lifting hook of the lifting appliance 100 is lower than the lifting lug of the muck box; s5, moving the trolley to the position of the dregs box; s6, lifting the lifting appliance 100 until the lifting hook is hung on the lifting lug of the muck box; s7, detecting whether the lifting hook lifting lug can be firmly hung; s8, lifting the muck box to an unloading height; s8, moving the cart and the trolley to an unloading position; s9, hooking the turning plate to the bottom of the dregs box, and simultaneously lowering the lifting appliance 100 so as to turn over the dregs box; and S10, resetting. The gantry crane automatic hoisting system and method provided by the application can adopt the hoisting tool 100 with different structures including the prior art, and the automatic hoisting program can be adjusted according to the structure of the hoisting tool 100.

It should be understood that structures and/or methods in the various embodiments provided herein may be combined, modified and/or altered to form new embodiments. Such solutions should also be included within the scope of the protection claimed in the present application without inventive effort.

Numerous specific examples are provided in the embodiments provided herein, with the understanding that these examples are set forth merely to illustrate embodiments of the present application in detail and are not limiting of the present application. Embodiments in this application may be practiced without these specific examples. Methods, structures, and/or techniques well known to those skilled in the art have not been shown in detail in some embodiments so as not to obscure an understanding of this application.

Although preferred embodiments of the present application have been shown and described herein, it will be readily understood by those skilled in the art that these embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the application. It should be understood that various alternatives to the embodiments of the present application described herein are optionally employed in practicing the present application. It is intended that the scope of the present application be defined by the claims and that the method and structure within the scope of these claims and their equivalents be covered thereby.

Claims (10)

1. An automatic hoisting system of gantry crane, which is characterized by comprising:

the device comprises a cart mechanism, a trolley mechanism, a lifting mechanism and a turning plate mechanism;

the cart mechanism comprises a cart main body and a cart running device; the large vehicle body comprises upright posts positioned at two sides of a construction track and a cross beam crossing the construction track, and the upright posts and the cross beam are connected to form a door-shaped structure; the cart running device is arranged below the upright post and is configured to drive the cart main body to move along the construction track direction;

the trolley mechanism comprises a trolley main body and a trolley travelling device; the trolley main body is positioned above the cross beam of the cart main body; the trolley travelling device is arranged between the trolley main body and the cross beam and is configured to drive the trolley main body to move along the length direction of the cross beam;

the lifting mechanism comprises a driving winding drum, a steel wire rope and a lifting appliance (100); the drive reel is mounted on the trolley body, the drive reel is connected to the lifting appliance (100) through the steel wire rope, and the drive reel is configured to drive the lifting appliance (100) to move in the vertical direction; the lifting appliance (100) comprises a lifting beam (101), telescopic arms (102) which can extend and retract along two sides of the lifting beam (101), a hanging plate (103) which is positioned below the telescopic arms (102) and a detection switch (104) which is arranged in the hanging plate (103), wherein lifting lugs which are matched with the hanging plate (103) are arranged on two sides of a muck box to be lifted;

the panel turnover mechanism comprises a panel turnover hook mounted on the trolley body or the hanging beam (101), and the panel turnover hook is configured to hang at the bottom of the muck box so as to turn over the muck box in cooperation with the lifting mechanism;

the control systems of the cart running device, the trolley running device and the driving winding drum are all in communication connection with a PLC, absolute value encoders are further arranged in the cart running device, the trolley running device and the driving winding drum, the absolute value encoders are configured to acquire three-dimensional position information of the lifting appliance (100), and the PLC is configured to automatically control movement of the cart running device, the trolley running device and the driving winding drum according to the three-dimensional position information;

an anti-shake program is preset in the PLC, and the anti-shake program is configured to automatically adjust the speeds of the cart mechanism, the trolley mechanism and the lifting appliance (100) according to the three-dimensional position information; and

the lifting mechanism further comprises a metal flaw detection device for monitoring the state of the steel wire rope.

2. The gantry crane automatic hoisting system of claim 1, wherein vibration monitoring sensors are also provided in the cart running gear, the trolley running gear and the drive drum.

3. The gantry crane automatic hoisting system according to claim 1, wherein a main communication network of the gantry crane automatic hoisting system adopts a Modbus-TCP industrial communication network.

4. The gantry crane automatic hoisting system of claim 1, further comprising video monitoring devices disposed around the construction track.

5. The gantry crane automatic hoisting system of claim 4, wherein the video monitoring device has a face recognition function and a sound system, the video monitoring device being configured to issue a warning to expel a non-worker through the sound system when it is recognized that the worker enters the work area.

6. The gantry crane automatic hoisting system according to claim 1, characterized in that,

the absolute value encoder is a multi-turn absolute value encoder.

7. The gantry crane automatic hoisting system according to claim 1, characterized in that the hoisting tool (100) is further provided with an electronic scale for weighing the muck box.

8. The gantry crane automatic hoisting system of claim 1, wherein the gantry crane automatic hoisting system is capable of automatic operation, semi-automatic operation, or manual operation.

9. The gantry crane automatic hoisting system of claim 1, wherein the metal inspection device is a magnetic inspection device;

the magnetic flaw detection device is arranged at a rope outlet position below the driving winding drum and comprises a magnetic memory planning device (201), a weak magnetic detection device (202), a follow-up device (203) and a guide rail (204);

the magnetic memory planning device (201) is configured to apply an external magnetic field to the steel wire rope, the weak magnetic detection device (202) is configured to detect the magnetic field near the steel wire rope, and the follow-up device (203) is configured to drive the magnetic memory planning device (201) and the weak magnetic detection device (202) to swing together on the guide rail (204) along with the steel wire rope when the steel wire rope swings due to retraction.

10. A method for loading and unloading slag using the gantry crane automatic hoisting system of any one of claims 1-9, comprising the steps of:

s1, a muck box transport vehicle moves to a loading position and establishes communication with the gantry crane automatic hoisting system;

s2, the cart main body and the trolley main body move to the loading position;

s3, the lifting appliance (100) stretches out of the telescopic arm (102) and is lowered to a preset height;

s4, the lifting appliance (100) retracts the telescopic arm (102) to a preset limit, so that the hanging plate (103) is hung at the lifting lug of the muck box;

s5, lifting the lifting appliance (100) to an unloading height;

s6, the cart main body and the trolley main body move to unloading positions;

s7, hooking the turning plate to the bottom of the muck box, and simultaneously descending the lifting appliance (100) so as to turn over the muck box; and

s8, resetting.

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