Intelligent crane control method and system based on digitization

Abstract

The invention discloses an intelligent crane control method and system based on digitization, and belongs to the technical field of intelligent crane control, and the method comprises the steps: employing an AS5600 magnetic encoder to accurately recognize the angle change of an operation handle, improving the data transmission rate and the anti-interference capability through a CAN bus communication protocol, and combining a non-contact magnetic induction technology to reduce the energy consumption. Troubleshooting and maintenance are simplified through modular design, and the standby power consumption of the system is reduced through combination of a non-contact magnetic induction technology and a low-power-consumption circuit design; the control system is divided into independent functional units through the modular design, and the cable consumption is reduced through standardized interfaces; the CAN bus replaces a multi-core cable and is integrated with a photoelectric isolation and self-checking mechanism, so that the wiring complexity is reduced; the modular design supports rapid fault positioning and plug-and-play maintenance, and the labor cost is reduced; and through module unique ID tracing and a triple detection mechanism, the product quality consistency is ensured, a closed-loop optimization production process is formed, and the comprehensive operation cost is further reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of crane intelligent control, and specifically refers to a crane intelligent control method and system based on digitization. Background Art

[0002] With the country's promotion of high-quality development of the manufacturing industry, the crane industry is rapidly evolving from traditional manual operation and mechanical control modes to digitalization and intelligence;

[0003] However, the existing digital crane intelligent control system still has certain defects. The existing multi-module collaboration and high-precision magnetic induction technology have high professional requirements for system debugging and maintenance personnel; the application of CAN bus, polymer wear-resistant materials and wireless communication modules significantly increases hardware procurement and R&D costs, limiting the popularization of small and medium-sized enterprises; although the dual encoder backup and redundant transmission structure improve reliability, it leads to an increase in the overall energy consumption of the system; although the standardized interface supports expansion, the docking with some old equipment or non-standard protocol systems still requires additional adaptation and development. For this reason, a digital-based crane intelligent control method and system are proposed. Summary of the Invention

[0004] The purpose of the present invention is to provide a digital-based intelligent crane control method and system to solve the problems raised in the above background technology.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solution: a digital-based intelligent control method for a crane, comprising the following steps:

[0006] S1. Uses the AS5600 magnetic encoder to accurately identify changes in the operating handle angle, replacing traditional mechanical contacts with wireless electronic contacts to eliminate wear and extend equipment life.

[0007] S2, using CAN bus communication protocol to improve data transmission rate and anti-interference ability, for distributed control architecture and stable communication in complex environments;

[0008] S3, combining contactless magnetic induction technology to reduce energy consumption and simplifying troubleshooting and maintenance through modular design;

[0009] S4. Use wear-resistant materials to improve transmission and dust-proof components, and integrate CAN bus automatic fault detection function to ensure the long-term operation stability of the equipment;

[0010] S5. Divide independent functional modules and standardize production processes;

[0011] S6, equipped with zero-position self-locking, touch screen monitoring and adjustable seats, supports seamless connection between wireless devices and electrical systems.

[0012] Among them, the S1 integrates the AS5600 magnetic encoder for contactless and accurate identification of the operating handle angle, adopts a permanent magnet and encoder magnetic coupling design, and ensures adaptability to industrial environments through a dust-proof and waterproof sealing structure. It combines the interface to transmit angle data to the main control unit in real time, and uses filtering algorithms and calibration mapping to generate operating instructions; it uses digital signals to directly drive the actuator instead of physical switches, and integrates a zero-position calibration function to eliminate drift errors. At the same time, it uses the CAN bus and redundant design to achieve multi-node collaboration and improve system reliability.

[0013] Among them, the S2 integrates a standard CAN bus controller and transceiver, deploys CAN interfaces in the crane's main control unit, operating handle, and actuator, builds a bus topology, uses shielded twisted-pair cables for connection, and configures 120Ω terminal resistors to eliminate signal reflections. By defining standard frames, extended frame formats, and baud rates, it enables low-latency communication between the main control unit and distributed nodes, and supports dynamic priority allocation.

[0014] Among them, the S2 adopts differential signal transmission technology to offset electromagnetic interference in industrial environments; adds optoelectronic isolation modules at key nodes to isolate high-voltage noise; integrates a CAN bus error detection mechanism to automatically retransmit error frames and record fault logs; builds a CAN bus network in the actual crane scenario to verify the stability of simultaneous communication of multiple nodes; and passes EMC testing to verify the system's anti-interference ability in a strong electromagnetic interference environment.

[0015] Among them, the S3, contactless magnetic induction technology combined with low-power circuit design and real-time signal calibration algorithm, reduces system energy consumption; adopts modular design to divide functional units and standardize interfaces, reduces cable usage and performs rapid fault location and replacement; replaces multi-core cables with CAN bus and integrates optoelectronic isolation and self-test mechanisms, further simplifying wiring and maintenance processes.

[0016] Among them, the S4 uses polymer wear-resistant materials to improve transmission and dust-proof components, combines IP67-level sealing design to enhance the equipment's resistance to environmental corrosion, and integrates a CAN bus automatic fault detection mechanism for rapid fault location and safe isolation; through redundant transmission structure and environmental adaptability testing, the equipment can operate stably for a long time under heavy loads, high-frequency start-stop and harsh working conditions.

[0017] Among them, the S5 divides the crane control system into standardized functional modules, defines unified physical and data interfaces, and combines automated production processes with an AI quality inspection system. Through a triple detection mechanism and module unique ID traceability, it further optimizes maintenance efficiency, designs replacement manuals and a modular spare parts library to shorten the replacement time of high-frequency fault modules, and standardizes the management of the entire production and maintenance process through cross-departmental collaboration and data-driven continuous improvement mechanisms.

[0018] The S6 integrates a zero-position self-locking function and a touch screen monitoring system, combined with an adjustable electric seat to enhance operational convenience and comfort. It also uses Wi-Fi and Bluetooth dual-mode wireless communication modules and a redundant connection mechanism to seamlessly integrate the wireless device with the crane's electrical system. Through EMC compatibility testing and encrypted transmission technology, the system operates safely and stably in complex industrial environments.

[0019] The file data migration system based on multi-source heterogeneous data includes:

[0020] Core perception module: uses contactless magnetic induction technology to obtain handle angle data and generate precise operating instructions;

[0021] Communication and control module: Builds a distributed control network based on CAN bus and differential signal transmission, supporting multi-node low-latency communication;

[0022] Energy and Modular Design Module: Combines low-power sensing with modular interface design to reduce cabling and optimize maintenance processes;

[0023] Hardware reliability and protection module: uses wear-resistant materials and IP67-level sealing structure to enhance resistance to environmental corrosion, and integrates fault detection mechanism;

[0024] Production and maintenance management module: Optimize product quality consistency and spare parts replacement efficiency through standardized module division and automated testing system;

[0025] Human-machine interaction and wireless integration module: Integrates zero-position self-locking, touch screen monitoring and wireless communication functions to optimize operational convenience and system adaptability.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. This invention uses the CAN bus protocol to design shielded twisted pair cables with 120Ω terminal resistors to effectively suppress electromagnetic interference. It defines standard frames, extended frame formats, and a dynamic priority allocation mechanism to shorten communication delays between the main control unit and distributed nodes and support real-time collaborative control. Differential signal transmission technology and optoelectronic isolation modules further isolate high-voltage noise, ensuring stable operation of key nodes under high-voltage conditions. The automatic retransmission mechanism and fault log recording function can quickly locate communication anomalies and, in conjunction with EMC testing and certification, verify the reliability of the system in strong electromagnetic interference environments. The CAN bus replaces multi-core cables to reduce the failure rate caused by wiring errors. It also supports modular expansion and provides a flexible interface for subsequent function upgrades.

[0028] 2. This invention combines contactless magnetic induction technology with low-power circuit design to reduce system standby power consumption. The modular design divides the control system into independent functional units, and the standardized interface reduces cable usage, lowering material and installation costs. The CAN bus replaces multi-core cables and integrates optoelectronic isolation and self-test mechanisms, reducing wiring complexity and shortening commissioning time. The modular design supports rapid fault location and plug-and-replace maintenance, reducing labor costs. Unique module ID traceability and triple detection mechanisms ensure product quality consistency, forming a closed-loop optimized production process and further reducing overall operating costs.

[0029] 3. The present invention extends the life of transmission components through the use of polymer wear-resistant materials and IP67-level sealing design. The CAN bus automatic fault detection mechanism shortens fault location time through heartbeat packet monitoring and fault code recording. Combined with the redundant transmission structure, the backup system automatically takes over in the event of a single point failure, avoiding equipment downtime. The fault isolation mechanism prevents local faults from spreading to the global system, thereby improving overall reliability.

[0030] 4. The present invention eliminates angle drift errors through the zero-position self-locking function combined with the zero-position calibration of the AS5600 magnetic encoder, ensures that unauthorized operations are invalid, and improves operational safety; the touch screen monitoring system displays the load weight, movement speed and fault log in real time, supports gesture sliding, voice input and physical button emergency shutdown, and improves operational efficiency; the adjustable electric seat is linked to personalized settings through the CAN bus, and the built-in pressure sensor realizes automatic sleep when the seat is left, reducing energy waste; Wi-Fi and Bluetooth dual-mode communication modules and redundant connection mechanisms support the access of wireless remote controls, AR glasses and other devices, increasing the availability of remote operation; AES-256 encryption transmission technology ensures the security of wireless communication, and verifies the stability in complex industrial environments through EMC compatibility testing, ultimately achieving a dual improvement in operational convenience and system adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 The operation process of the digital crane intelligent control method of the present invention is as follows Figure 1 ;

[0032] Figure 2 The operation process of the digital crane intelligent control method of the present invention is as follows Figure 2 ;

[0033] Figure 3 This is a structural diagram of the digital crane intelligent control system of the present invention. DETAILED DESCRIPTION

[0034] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0035] Example

[0036] See also Figure 1-Figure 3 As shown, the present invention provides a technical solution: comprising the following steps:

[0037] S1. Uses the AS5600 magnetic encoder to accurately identify changes in the operating handle angle, replacing traditional mechanical contacts with wireless electronic contacts to eliminate wear and extend equipment life.

[0038] S2, using CAN bus communication protocol to improve data transmission rate and anti-interference ability, for distributed control architecture and stable communication in complex environments;

[0039] S3, combining contactless magnetic induction technology to reduce energy consumption and simplifying troubleshooting and maintenance through modular design;

[0040] S4. Use wear-resistant materials to improve transmission and dust-proof components, and integrate CAN bus automatic fault detection function to ensure the long-term operation stability of the equipment;

[0041] S5. Divide independent functional modules and standardize production processes;

[0042] S6, equipped with zero-position self-locking, touch screen monitoring and adjustable seats, supports seamless connection between wireless devices and electrical systems.

[0043] Among them, the S1 integrates the AS5600 magnetic encoder for contactless and accurate identification of the operating handle angle, adopts a permanent magnet and encoder magnetic coupling design, and ensures adaptability to industrial environments through a dust-proof and waterproof sealing structure. It combines the interface to transmit angle data to the main control unit in real time, and uses filtering algorithms and calibration mapping to generate operating instructions; it uses digital signals to directly drive the actuator instead of physical switches, and integrates a zero-position calibration function to eliminate drift errors. At the same time, it uses the CAN bus and redundant design to achieve multi-node collaboration and improve system reliability.

[0044] Among them, the S2 integrates a standard CAN bus controller and transceiver, deploys CAN interfaces in the crane's main control unit, operating handle, and actuator, builds a bus topology, uses shielded twisted-pair cables for connection, and configures 120Ω terminal resistors to eliminate signal reflections. By defining standard frames, extended frame formats, and baud rates, it enables low-latency communication between the main control unit and distributed nodes, and supports dynamic priority allocation.

[0045] Among them, the S2 adopts differential signal transmission technology to offset electromagnetic interference in industrial environments; adds optoelectronic isolation modules at key nodes to isolate high-voltage noise; integrates a CAN bus error detection mechanism to automatically retransmit error frames and record fault logs; builds a CAN bus network in the actual crane scenario to verify the stability of simultaneous communication of multiple nodes; and passes EMC testing to verify the system's anti-interference ability in a strong electromagnetic interference environment.

[0046] Among them, the S3, contactless magnetic induction technology combined with low-power circuit design and real-time signal calibration algorithm, reduces system energy consumption; adopts modular design to divide functional units and standardize interfaces, reduces cable usage and performs rapid fault location and replacement; replaces multi-core cables with CAN bus and integrates optoelectronic isolation and self-test mechanisms, further simplifying wiring and maintenance processes.

[0047] Among them, the S4 uses polymer wear-resistant materials to improve transmission and dust-proof components, combines IP67-level sealing design to enhance the equipment's resistance to environmental corrosion, and integrates a CAN bus automatic fault detection mechanism for rapid fault location and safe isolation; through redundant transmission structure and environmental adaptability testing, the equipment can operate stably for a long time under heavy loads, high-frequency start-stop and harsh working conditions.

[0048] Among them, the S5 divides the crane control system into standardized functional modules, defines unified physical and data interfaces, and combines automated production processes with an AI quality inspection system. Through a triple detection mechanism and module unique ID traceability, it further optimizes maintenance efficiency, designs replacement manuals and a modular spare parts library to shorten the replacement time of high-frequency fault modules, and standardizes the management of the entire production and maintenance process through cross-departmental collaboration and data-driven continuous improvement mechanisms.

[0049] The S6 integrates a zero-position self-locking function and a touch screen monitoring system, combined with an adjustable electric seat to enhance operational convenience and comfort. It also uses Wi-Fi and Bluetooth dual-mode wireless communication modules and a redundant connection mechanism to seamlessly integrate the wireless device with the crane's electrical system. Through EMC compatibility testing and encrypted transmission technology, the system operates safely and stably in complex industrial environments.

[0050] The file data migration system based on multi-source heterogeneous data includes:

[0051] Core perception module: uses contactless magnetic induction technology to obtain handle angle data and generate precise operating instructions;

[0052] Communication and control module: Builds a distributed control network based on CAN bus and differential signal transmission, supporting multi-node low-latency communication;

[0053] Energy and Modular Design Module: Combines low-power sensing with modular interface design to reduce cabling and optimize maintenance processes;

[0054] Hardware reliability and protection module: uses wear-resistant materials and IP67-level sealing structure to enhance resistance to environmental corrosion, and integrates fault detection mechanism;

[0055] Production and maintenance management module: Optimize product quality consistency and spare parts replacement efficiency through standardized module division and automated testing system;

[0056] Human-machine interaction and wireless integration module: Integrates zero-position self-locking, touch screen monitoring and wireless communication functions to optimize operational convenience and system adaptability.

[0057] Working principle: Intelligent control of cranes is achieved through the collaboration of multiple technologies: First, the operating handle integrates the AS5600 magnetic encoder, which captures angle changes contactlessly through permanent magnets and magnetic coupling design, generates precise operating instructions in combination with filtering algorithms and calibration mapping, and transmits data to the main control unit in real time through the CAN bus, replacing traditional mechanical contacts, eliminating wear and extending equipment life; the main control unit builds a distributed control network through the CAN bus, using shielded twisted pair and differential signal transmission technology, combined with optoelectronic isolation modules and redundant design to ensure high anti-interference ability and low-latency communication in complex industrial environments; the system combines contactless magnetic induction technology with low-power circuit design to reduce energy consumption, while reducing cables through modular division and standardized interfaces It supports rapid fault location and replacement, and optimizes maintenance efficiency; the transmission components adopt polymer wear-resistant materials and IP67-level sealing structure, integrate CAN bus automatic fault detection mechanism, and cooperate with redundant transmission structure to ensure the long-term stability of the equipment under heavy load and high-frequency start-stop conditions; the production end improves product quality consistency through modular design and automated detection system, combines triple detection mechanism with module unique ID traceability, and shortens the replacement time of high-frequency fault modules; the operation end is equipped with zero-position self-locking, touch screen monitoring and adjustable electric seat, supports Wi-Fi and Bluetooth dual-mode wireless communication and encrypted transmission technology, improves operation convenience and system security in complex environments, and ultimately realizes comprehensive optimization of cranes in terms of high efficiency, energy saving, stability and intelligent maintenance.

[0058] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

[0059] The present invention and its embodiments are described above. This description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if a person skilled in the art is inspired by this and, without departing from the purpose of the present invention, designs structures and embodiments similar to this technical solution without inventiveness, they shall fall within the scope of protection of the present invention.

Claims

1. A digital-based intelligent crane control method, characterized in that: The following steps are involved: S1. Use magnetic encoder to accurately identify the angle change of the operating handle; S2. Use CAN bus communication protocol to improve data transmission rate and anti-interference ability, and achieve stable communication in distributed control architecture and complex environment; S3, combining contactless magnetic induction technology to reduce energy consumption and simplifying troubleshooting and maintenance through modular design; S4. Use wear-resistant materials to improve transmission and dust-proof components, and integrate CAN bus automatic fault detection function to ensure the long-term operation stability of the equipment; S5. Divide independent functional modules and standardize production processes; S6, equipped with zero-position self-locking, touch screen monitoring and adjustable seats, supports seamless connection between wireless devices and electrical systems.

2. The digital-based intelligent crane control method according to claim 1, characterized in that: The S1 integrates an AS5600 magnetic encoder for contactless and precise identification of the operating handle angle. It uses a permanent magnet and encoder magnetic coupling design, and a dust-proof and waterproof sealing structure to ensure adaptability to industrial environments. It uses an interface to transmit angle data to the main control unit in real time, and uses filtering algorithms and calibration mapping to generate operating instructions. It directly drives the actuator with digital signals instead of physical switches, and integrates a zero-position calibration function to eliminate drift errors. At the same time, it uses the CAN bus and redundant design to achieve multi-node collaboration and improve system reliability.

3. The digital-based intelligent crane control method according to claim 1, characterized in that: The S2 integrates a standard CAN bus controller and transceiver, deploys CAN interfaces in the crane's main control unit, operating handle, and actuator, builds a bus topology, uses shielded twisted-pair cables for connection, and configures 120Ω terminal resistors to eliminate signal reflections. By defining standard frames, extended frame formats, and baud rates, it enables low-latency communication between the main control unit and distributed nodes, and supports dynamic priority allocation.

4. The digital-based intelligent crane control method according to claim 1, characterized in that: The S2 system uses differential signal transmission technology to offset electromagnetic interference in industrial environments; adds optoelectronic isolation modules at key nodes to isolate high-voltage noise; integrates a CAN bus error detection mechanism to automatically retransmit error frames and record fault logs; and builds a CAN bus network in an actual crane scenario to verify the stability of simultaneous multi-node communication. Through EMC testing, the system's anti-interference ability in a strong electromagnetic interference environment is verified.

5. The digital-based intelligent crane control method according to claim 1, characterized in that: The S3 combines contactless magnetic induction technology with low-power circuit design and real-time signal calibration algorithms to reduce system energy consumption. It adopts a modular design to divide functional units and standardize interfaces, reducing cable usage and enabling rapid fault location and replacement. It replaces multi-core cables with the CAN bus and integrates optoelectronic isolation and self-test mechanisms to further simplify wiring and maintenance processes.

6. The digital-based intelligent crane control method according to claim 1, characterized in that: The S4 uses wear-resistant polymer materials to improve transmission and dust-proof components, combines an IP67-level sealing design to enhance the equipment's resistance to environmental corrosion, and integrates a CAN bus automatic fault detection mechanism for rapid fault location and safe isolation. Through redundant transmission structure and environmental adaptability testing, the equipment can operate stably for a long time under heavy loads, high-frequency start-stop and harsh working conditions.

7. The digital-based intelligent crane control method according to claim 1, characterized in that: The S5 divides the crane control system into standardized functional modules, defines unified physical and data interfaces, and integrates automated production processes with an AI-powered quality inspection system. It further optimizes maintenance efficiency through a triple detection mechanism and unique module ID traceability. A replacement manual and modular spare parts library are designed to shorten the replacement time of frequently faulty modules. Through cross-departmental collaboration and a data-driven continuous improvement mechanism, standardized management of the entire production and maintenance process is implemented.

8. The digital-based intelligent crane control method according to claim 1, characterized in that: The S6 integrates a zero-position self-locking function and a touchscreen monitoring system, combined with an adjustable electric seat, to enhance operational convenience and comfort. It also uses Wi-Fi and Bluetooth dual-mode wireless communication modules and a redundant connection mechanism, seamlessly integrating the wireless device with the crane's electrical system. Through EMC compatibility testing and encrypted transmission technology, the system ensures safe and stable operation in complex industrial environments.

9. File data migration system based on multi-source heterogeneous data, including: Core perception module: uses contactless magnetic induction technology to obtain handle angle data and generate precise operating instructions; Communication and control module: Builds a distributed control network based on CAN bus and differential signal transmission, supporting multi-node low-latency communication; Energy and Modular Design Module: Combining low-power sensing with modular interface design; Hardware reliability and protection module: uses wear-resistant materials and IP67-level sealing structure to enhance resistance to environmental corrosion, and integrates fault detection mechanism; Production and maintenance management module: Optimize product quality consistency and spare parts replacement efficiency through standardized module division and automated testing system; Human-machine interaction and wireless integration module: Integrates zero-position self-locking, touch screen monitoring and wireless communication functions to optimize operational convenience and system adaptability.

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