Loading control system and method for grab crane

Abstract

The invention discloses a grab bucket crane loading control system and method, and relates to the technical field of loading and unloading automation, a weighing sensing module is integrated in a grab bucket to collect the actual weight of a single-bucket material in real time, and a bucket number calculation module is combined to dynamically update the material density and correct the number of residual feeding buckets in a closed loop mode, so that the loading total amount precision is remarkably improved; the problem of overload and underload caused by material density fluctuation is effectively solved, meanwhile, space coordinates and swing angles are monitored in real time through the grab bucket positioning module, angle, speed and height compensation instructions are dynamically generated through the motion control module, and real-time correction of drop point deviation is achieved. In addition, the accumulated weight and the balance index of each subarea of the compartment are calculated in real time by means of the loading balance module, the falling point is automatically switched to the lowest loading area, uniform material distribution is ensured, the unbalance loading risk is avoided, and the compartment space utilization rate is increased.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of loading and unloading automation, and more particularly, to a control system and method for a grab crane loading truck. BACKGROUND

[0002] The grab crane refers to a hoisting machine equipped with a grab bucket, mainly used in places such as ports, wharfs, stations, yards, mines, etc., for loading various bulk materials, logs, minerals, coal, sand and gravel materials, earthwork, etc. The grab crane is an automatic material taking machine, whose grabbing and unloading actions are controlled by the ship unloader driver without the need for auxiliary personnel, thereby saving auxiliary work time and greatly improving the loading and unloading efficiency. In the current bulk material (such as coal, ore, grain, etc.) loading operation, the grab crane is a commonly used device. However, the existing grab crane loading control system generally has the following main defects:

[0003] Low loading accuracy and reliance on experience: The existing system usually cannot measure the actual weight of the material put into the car by the grab bucket in real time and accurately. The calculation of the initial loading bucket number is often based on the preset standard density of the material and the nominal volume of the grab bucket, but the actual density of the material is significantly affected by factors such as humidity and particle size. This results in the system either relying too much on the experience of the operator's estimate or being unable to dynamically adjust the remaining bucket number during the loading process, ultimately causing the total loading amount to deviate too much, resulting in overloading or underloading, affecting transportation safety, efficiency and settlement accuracy.

[0004] Uneven material distribution and poor drop point control: The existing system lacks the ability to accurately monitor and dynamically compensate for the spatial position and attitude of the grab bucket (especially the swing). During the movement and release of the grab bucket, especially when affected by wind speed, there is often a large deviation between the actual drop point and the target drop point (drop point prediction deviation). At the same time, the system cannot intelligently perceive the cumulative loading amount difference in each area of the car. This results in uneven accumulation of materials in the car, such as local overloading or underloading, which not only affects the utilization of car space and increases the workload of the flat car, but also may cause uneven loading and affect the safety of the train.

[0005] These defects seriously restrict the efficiency, accuracy and safety of the loading operation, and an integrated control system and method that can integrate real-time weighing, accurate positioning, intelligent calculation and dynamic compensation is urgently needed to solve the above problems. SUMMARY

[0006] Therefore, the present application provides a control system and method for a grab crane loading truck to solve the problems of low loading accuracy and reliance on experience and uneven material distribution and poor drop point control.

[0007] In one aspect, the application provides a grab crane loading control system, comprising: a weighing sensor module, a bucket number calculation module, a total amount control module, a grab positioning module, a motion control module, a loading balancing module, a communication coordination module and a driving module, wherein,

[0008] The weighing sensor module is coupled with the bucket number calculation module through the communication coordination module, is arranged in the grab of the grab crane, and is used for collecting the actual weight W of the material in the grab each time of feeding. a The actual weight W is sent to the bucket number calculation module.

[0009] The bucket number calculation module is coupled with the weighing sensor module, the total amount control module and the driving module through the communication coordination module, is used for executing target loading amount setting, initial bucket number calculation, density dynamic updating, remaining loading amount updating and remaining bucket number prediction, and comprises:

[0010] Setting a target loading amount W of the carriage t And a grab calibration volume V g .

[0011] According to the formula , an initial feeding bucket number n0 is calculated, wherein p0 is a standard material density.

[0012] After each feeding, the remaining loading amount W r is updated as W t = W a -∑W a , and is sent to the total amount control module.

[0013] According to the formula , a measured density p s of the present feeding is calculated, and in combination with the formula , a remaining bucket number n s is calculated, and the remaining bucket number n r is transmitted to the driving module.

[0014] The driving module is coupled with the bucket number calculation module and the total amount control module, is used for receiving a bucket number instruction, and drives and adjusts the grab crane to execute a feeding action.

[0015] The total amount control module is coupled with the driving module, is used for sending a stop instruction to the driving module when the remaining loading amount W g calculated by the bucket number calculation module is less than or equal to 0.

[0016] The grab positioning module is arranged in the grab of the grab crane, is used for obtaining spatial coordinates (X g , Y g , Z g ) and a swing angle θ of the grab.Let Y be the coordinate of the grab bucket in the horizontal direction of the horizontal plane. g Let Z be the coordinate of the grab bucket along the vertical axis in the horizontal plane. g This indicates the coordinates of the grab bucket along the vertical axis.

[0017] The motion control module is coupled to the drive module and is used to generate a grab bucket braking command based on the landing point prediction deviation η, and output the angle correction amount Δθ and the speed adjustment value v. adj and height compensation value H c The data is sent to the drive module to drive the grab crane to perform trajectory correction actions, including:

[0018] Obtain the carriage partition coordinate sequence {(X1,Y1,Z1),(X2,Y2,Z2),...,(X n ,Y n Z n At the same time, obtain the carriage coordinates (X) of the current target landing point. i ,Y i Z i );

[0019] According to the formula The horizontal deviation D was calculated. h ;

[0020] According to the formula η=D h ×sinθ+|Z g -Z i The predicted landing point deviation η is calculated.

[0021] Preset maximum allowable landing point deviation η max And compare the landing point prediction deviation η with the preset maximum allowable landing point deviation η max Compare the results; if η > η max If the angle correction Δθ is calculated according to the formula Δθ=k·η, the grab bucket braking command is generated and sent to the drive module. The drive module adjusts the grab bucket swing angle according to the angle correction Δθ, where k is the correction coefficient.

[0022] According to the formula The calculated speed regulation value v adj The drive module adjusts the speed value v. adj Adjust the crane's moving speed, where k v v is the velocity decay coefficient. r Preset a reference speed for the grab crane;

[0023] According to formula H c =Z i +k z ·|Z g -Z i The height compensation value H is calculated.c wherein k z is a height compensation coefficient;

[0024] The height compensation value H c is sent to the driving module, and the driving module corrects the release height of the grab bucket according to the height compensation value H c .

[0025] The loading balancing module is coupled with the driving module, and is used for monitoring the cumulative weight W si of each subzone of the carriage, calculating a loading balancing index λ, and switching the target drop point to a low-load subzone, including:

[0026] The cumulative weight W s1 , W s2 ,..., W sm of each subzone of the carriage is monitored in real time.

[0027] The loading balancing index λ is calculated according to the formula .

[0028] A preset loading balancing index threshold λ th is set, and the loading balancing index λ is compared with the loading balancing index threshold λ th . If λ > λ th , the drop point coordinate sequence is re-planned, and the target drop point is switched to the low-load subzone.

[0029] The communication coordination module is coupled with the weighing sensor module, the bucket number calculation module, the total quantity control module, the grab bucket positioning module, the motion control module, the loading balancing module, and the driving module, and is used for establishing a high-speed data channel between the weighing sensor module, the bucket number calculation module, the total quantity control module, the grab bucket positioning module, the motion control module, the loading balancing module, and the driving module, and realizing real-time instruction transmission.

[0030] Optionally, the grab bucket positioning module is internally provided with a GNSS positioning unit and an inclination sensor. The spatial coordinates (X g , Y g , Z g ) of the grab bucket are obtained through the GNSS positioning unit, and the swing angle θ of the grab bucket is obtained through the inclination sensor.

[0031] Optionally, the grab bucket positioning module comprises a wind speed sensor. The wind speed sensor is used for detecting a real-time wind speed and sending the real-time wind speed to the driving module. When the real-time wind speed F w > 8 m / s, the preset reference speed vr of the grab bucket crane is lowered to 80% through the driving module.

[0032] Optionally, a safety early warning module is also included, which is coupled to the grab positioning module and the drive module respectively through the communication coordination module, for implementing a three-level risk prevention and control strategy, including:

[0033] Level 1 Warning: When the real-time wind speed F w When the speed is greater than 10 m / s, an audible and visual alarm will be triggered;

[0034] Secondary braking: Preset wire rope tension threshold T for grab crane max When the tension T of the wire rope of the grab crane s >0.95T max At that time, the grab crane was forcibly stopped.

[0035] Level 3 Power Failure: Preset stress threshold σ for the wire rope structure of the grab crane. th When the structural stress σ of the grab crane wire rope is detected to be greater than σ, th Cut off the main power supply and lock the grab crane.

[0036] Optionally, the security early warning module, after activating the three-level risk prevention and control strategy, includes:

[0037] A safety warning signal is sent to the drive module, which then activates the emergency self-locking device to fix the grab bucket position.

[0038] A safety warning signal is sent to the grab positioning module, and the GNSS positioning unit inside the grab positioning module records the hovering coordinates (X). e ,Y e Z e );

[0039] Record wind speed, wire rope tension data of grab crane, and instantaneous values ​​of structural stress of grab crane wire rope.

[0040] Optionally, the communication coordination module employs dual-channel redundant transmission, including:

[0041] The main channel synchronously transmits the spatial coordinates (X) of the grab bucket at a frequency of 100Hz. g ,Y g Z g ), swing angle θ and landing point prediction deviation η;

[0042] The backup channel transmits weighing data and safety warning signals at a frequency of 50Hz.

[0043] Automatically switch to backup channel when the main channel delay is greater than 20ms.

[0044] Optionally, the communication coordination module performs the following steps when the backup channel is activated:

[0045] Start data compression engine, adopt difference value coding compression for spatial coordinates (X g ,Y g ,Z g ) of grab bucket;

[0046] Adopt run coding compression for weighing data;

[0047] When compression ratio is greater than or equal to 50%, maintain 50Hz transmission; when compression ratio is less than 50%, reduce frequency to 25Hz.

[0048] Optionally, the bucket number calculation module performs bucket number pre-check before first feeding, including:

[0049] According to historical loading data, calculate density fluctuation range ρ min -ρ max ;

[0050] Generate bucket number safety interval n safe ;

[0051] Compare initial feeding bucket number n0 with bucket number safety interval n safe , if initial feeding bucket number n0 exceeds bucket number safety interval n safe , trigger confirmation process.

[0052] On the other hand, the application also provides a grab bucket crane loading control method, applying the grab bucket crane loading control system, including steps of:

[0053] Input car compartment target loading capacity W t and grab bucket calibration volume V g , at this time, the bucket number calculation module calculates initial feeding bucket number n0 according to formula ;

[0054] Loading control operation includes collecting actual weight W a of material in grab bucket at each feeding time by using weighing sensor module, and obtaining spatial coordinates (X g ,Y g ,Z g ) of grab bucket and swing angle θ;

[0055] Car loading operation is performed, after each feeding, update remaining loading capacity W r =W t -ΣW a by using bucket number calculation module, and calculate measured density ρ a of this feeding according to formula ;

[0056] Calculate landing point prediction deviation η by using motion control module:

[0057] Obtain the carriage partition coordinate sequence {(X1,Y1,Z1),(X2,Y2,Z2),...,(X n ,Y n Z n At the same time, obtain the carriage coordinates (X) of the current target landing point. i ,Y i Z i );

[0058] According to the formula The horizontal deviation D was calculated. h ;

[0059] According to the formula η=D h ×sinθ+|Z g -Z i The predicted landing point deviation η is calculated.

[0060] Preset maximum allowable landing point deviation η max And compare the landing point prediction deviation η with the preset maximum allowable landing point deviation η max Compare the results; if η > η max If this occurs, a grab braking command is generated and sent to the drive module. The angle correction Δθ is calculated using the formula Δθ=k·η. The drive module then adjusts the grab swing angle based on the angle correction Δθ. And according to the formula... The calculated speed regulation value v adj The drive module adjusts the speed value v. adj Adjust the crane's moving speed; simultaneously, according to formula H... c =Z i +k z ·|Z g -Z i The height compensation value H is calculated. c The drive module is based on the height compensation value H c Adjust the grab release height;

[0061] The loading balance module monitors the cumulative weight W of each section of the car body in real time. s1 W s2 ,...,W sm And according to the formula The load balancing index λ is calculated, and the load balancing index threshold λ is preset. th And compare the load balancing index λ with the load balancing index threshold λ th Comparing them, if λ > λ th If so, the landing point coordinate sequence is replanned, and the target landing point is switched to the low-load partition;

[0062] The Dou Shu calculation module calculates based on the formula. The remaining number of bushels n is calculated. sAnd the remaining number of buckets n s is transmitted to the driving module, and the driving module is used to continue to control the grab crane to carry out the loading operation until the total amount control module monitors that W r ≤0, a stop instruction is sent to the driving module, and the driving module is used to control the grab crane to stop loading.

[0063] Optionally, in the loading control operation, the wind speed, the steel wire rope tension of the grab crane and the structural stress of the steel wire rope of the grab crane are monitored in real time, including:

[0064] When the real-time wind speed F w >10m / s, an audible and visual alarm is issued;

[0065] A preset steel wire rope tension threshold T max of the grab crane is set, when the steel wire rope tension T s of the grab crane is greater than 0.95T max , the grab crane is forced to hover;

[0066] A preset structural stress threshold σ th of the steel wire rope of the grab crane is set, when the structural stress σ of the steel wire rope of the grab crane is detected to be greater than σ th , the main power is cut off and the grab crane is locked.

[0067] Compared with the prior art, the grab crane loading control system and the control method provided by the application at least achieve the following beneficial effects:

[0068] The grab crane loading control system of the application sets a weighing sensor module in the grab bucket, collects actual weight data of each feeding in real time, and uses the real-time weight data to dynamically update the measured density of the material by combining the calibrated volume of the grab bucket through the bucket number calculation module, and recalculates the remaining number of buckets accordingly. By adopting a closed-loop control mechanism based on the actual feeding weight and the dynamically updated density, the influence of material density fluctuation is effectively overcome, the cumulative error caused by inaccurate preset of the standard density is greatly reduced, and finally the target loading amount is accurately stopped when the total amount control module reaches the target loading amount, achieving high-precision control of the total loading amount and reducing the risk of overloading and underloading.

[0069] The grab crane loading control system of the application integrates a GNSS positioning unit and an inclination sensor through a grab bucket positioning module, and accurately obtains the spatial coordinates and swing angle of the grab bucket in real time. The motion control module calculates the drop point prediction deviation using these data, and when the deviation exceeds a preset threshold, the angle correction amount, speed adjustment value and height compensation value are generated and output to the driving module in real time, so as to dynamically correct the grab bucket trajectory and ensure that the material is accurately fed to the target drop point.

[0070] The grab crane loading control system of the present application monitors the cumulative weight of each partition of the car in real time through the loading balancing module, and calculates the loading balancing index, when the index exceeds the preset threshold, it indicates that the material distribution in the car is not balanced, the system will automatically re-plan the landing point coordinate sequence, and the subsequent material is preferentially put into the partition with the lowest load at present, by using this intelligent landing point dynamic adjustment strategy, the problem of local overloading or underloading of materials in the car is effectively avoided, the car space utilization and loading uniformity are improved, the transportation risk caused by unbalanced load is reduced, and the workload of the subsequent flat car is reduced.

[0071] Of course, the implementation of any product of the present application does not necessarily require all the technical effects described above to be achieved simultaneously.

[0072] Other features of the present application, and their advantages, will become apparent from the following detailed description of illustrative embodiments of the present application, with reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0073] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present application and, together with the description, serve to explain the principles of the present application.

[0074] Figure 1 is a structure schematic diagram of a grab crane loading control system provided by the present application;

[0075] Figure 2 is another structure schematic diagram of a grab crane loading control system provided by the present application;

[0076] Figure 3 is a flow chart of a grab crane loading control method provided by the present application. DETAILED DESCRIPTION

[0077] Various illustrative embodiments of the present application will now be described in detail with reference to the accompanying figures. It is noted that the relative arrangements, numerical expressions, and values of components and steps set forth in these embodiments are not limiting to the scope of the present application, unless otherwise specifically stated.

[0078] The following description of at least one illustrative embodiment is merely exemplary in nature and is in no way intended to limit the present application or its application or uses.

[0079] Techniques, methods, and devices known to those of ordinary skill in the relevant art can not be discussed in detail herein, but should be considered as part of the specification, where appropriate.

[0080] In all examples shown and discussed herein, any specific values should be interpreted as merely exemplary, and not as a limitation. Thus, other examples of the illustrative embodiments can have different values.

[0081] It should be noted that similar labels and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be discussed further in subsequent figures.

[0082] Example 1

[0083] Combination Figure 1 , Figure 1 This is a schematic diagram of a grab crane loading control system provided by the present invention. The grab crane loading control system of this embodiment includes: a weighing sensor module 1, a bucket count calculation module 6, a total quantity control module 4, a grab bucket positioning module 2, a motion control module 8, a loading balancing module 3, a communication coordination module 5, and a drive module 7.

[0084] Weighing sensor module 1 is coupled to bucket number calculation module 6 via communication coordination module 5 and is located inside the grab bucket of the grab crane. It is used to collect the actual weight W of the material in the grab bucket in real time for each feeding. a Send to the Dou Shu calculation module 6;

[0085] The hopper count calculation module 6 is coupled to the weighing sensor module 1, the total quantity control module 4, and the drive module 7 via the communication coordination module 5. It is used to perform target loading amount setting, initial hopper count calculation, density dynamic updating, remaining loading amount updating, and remaining hopper count prediction, including:

[0086] Set the target loading capacity W of the carriage t and the calibrated volume V of the grab bucket g ;

[0087] According to the formula The initial number of feeding hoppers n0 is calculated, where ρ0 is the standard material density;

[0088] Update the remaining loading quantity W after each feeding. r =W t -∑W a And send it to the total quantity control module 4;

[0089] According to the formula The measured density ρ of the material was calculated. a and in combination with formula The remaining number of bushels n is calculated. s and the remaining number of dou (a unit of volume) n s Passed to driver module 7;

[0090] The drive module 7 is coupled to the bucket number calculation module 6 and the total quantity control module 4 respectively, and is used to receive bucket number instructions and drive and adjust the grab crane to perform feeding actions;

[0091] The total amount control module 4 is coupled with the driving module 7, and is used for sending a stop instruction to the driving module 7 when the remaining loading amount W calculated by the bucket number calculation module 6 is less than or equal to 0. r ≤0, a stop instruction is sent to the driving module 7;

[0092] The bucket positioning module 2 is arranged in the bucket of the bucket crane, and is used for acquiring spatial coordinates (X g , Y g , Z g ) and a swing angle θ of the bucket, wherein X g represents a coordinate of the bucket in a horizontal plane transverse axis direction, Y g represents a coordinate of the bucket in a horizontal plane longitudinal axis direction, and Z g represents a coordinate of the bucket in a vertical plane axis direction.

[0093] The motion control module 8 is coupled with the driving module 7, and is used for generating a bucket braking instruction according to a landing point prediction deviation η, and outputting an angle correction amount Δθ, a speed adjustment value v adj , and a height compensation value H c to the driving module 7 to drive the bucket crane to perform a trajectory correction action, including:

[0094] A carriage partition coordinate sequence {(X1, Y1, Z1), (X2, Y2, Z2), …, (X n , Y n , Z n )} is acquired, and a carriage coordinate (X i , Y i , Z i ) of a current target landing point is acquired at the same time.

[0095] A horizontal deviation D h is calculated according to a formula .

[0096] A landing point prediction deviation η is calculated according to a formula η = D h × sin θ + |Z g -Z i |.

[0097] A preset maximum landing point deviation η max is set, and the landing point prediction deviation η is compared with the preset maximum landing point deviation η max , if η > η max , a bucket braking instruction is generated to the driving module 7, and an angle correction amount Δθ is calculated according to a formula Δθ = k·η, and the driving module 7 adjusts a bucket swing angle according to the angle correction amount Δθ, wherein k is a correction coefficient.

[0098] A speed adjustment value v adj is calculated according to a formula , and the driving module 7 adjusts a speed of the bucket crane according to the speed adjustment value vadj Adjust the crane moving speed, wherein k v is the speed attenuation coefficient, v r is the preset reference speed of the grab bucket crane;

[0099] According to the formula H c = Z i +k z ·|Z g -Z i |Calculate the height compensation value H c , wherein k z is the height compensation coefficient;

[0100] Send the height compensation value H c to the drive module 7, and the drive module 7 corrects the grab bucket release height according to the height compensation value H c ;

[0101] The loading balancing module 3 is coupled with the drive module 7, and is used to monitor the cumulative weight W si of each sub-zone of the carriage, calculate the loading balancing index λ, and switch the target landing point to the low-load sub-zone, including:

[0102] Real-time monitoring of the cumulative weight W s1 , W s2 ,..., W sm of each sub-zone of the carriage;

[0103] According to the formula , the loading balancing index λ is calculated;

[0104] The preset loading balancing index threshold λ th , and the loading balancing index λ is compared with the loading balancing index threshold λ th . If λ> λ th , the landing point coordinate sequence is re-planned, and the target landing point is switched to the low-load sub-zone;

[0105] The communication coordination module 5 is coupled with the weighing sensor module 1, the bucket number calculation module 6, the total quantity control module 4, the grab bucket positioning module 2, the motion control module 8, the loading balancing module 3, and the drive module 7, respectively, and is used to establish a high-speed data channel between the weighing sensor module 1, the bucket number calculation module 6, the total quantity control module 4, the grab bucket positioning module 2, the motion control module 8, the loading balancing module 3, and the drive module 7, and realize real-time instruction transmission.

[0106] Optionally, the weighing sensor module 1 adopts an HBM PW15C plate sensor. The weighing sensor module 1 outputs an analog signal or a digital signal to a local signal conditioner, converts it into a standard industrial signal, and the communication coordination module 5 uniformly manages through double-channel redundant transmission, or separately configures a signal sending element (such as a wireless transmitter 0) on the weighing sensor module 1.

[0107] This invention utilizes a weighing sensor module 1 to collect real-time actual weight data, accurately determining the weight of each feeding and providing a precise basis for subsequent calculations and control, effectively reducing total loading deviations caused by weight errors. Simultaneously, the hopper count calculation module 6 dynamically updates material density and predicts the remaining hopper count, overcoming the impact of material density fluctuations and significantly improving the accuracy of total loading, reducing the risk of overloading and underloading. Furthermore, the drive module 7 precisely executes the feeding action, ensuring the accuracy of each feeding and improving loading efficiency. In addition, the total loading control module 4 enables precise stopping, ensuring the total loading meets target requirements and preventing overloading or underloading.

[0108] It should be noted that when the grab positioning module 2 obtains the spatial coordinates of the grab, it needs to establish a coordinate axis. Of course, this coordinate axis is a virtual coordinate axis. The origin is set as the center point of the selected car floor or the geometric center of the loading area of ​​the car. The x-axis is set as parallel to the length direction of the car (from front to rear), the y-axis is set as parallel to the width direction of the car (from left to right), and the z-axis is set as the positive direction perpendicular to the ground and upward.

[0109] In this embodiment of the invention, the grab positioning module 2 accurately acquires the position and attitude information of the grab, providing accurate data for trajectory correction. Simultaneously, the motion control module 8 corrects the grab trajectory in real time, ensuring precise delivery of materials to the target landing point, thus improving landing accuracy and operational efficiency.

[0110] Optionally, when acquiring the car compartment coordinate sequence, the motion control module 8 acquires the car compartment coordinate sequence {(X1,Y1,Z1),(X2,Y2,Z2),...,(X... n ,Y n Z n At the same time, obtain the carriage coordinates (X) of the current target landing point. i ,Y i Z i ), where the carriage at the current target landing point is the target carriage to be loaded, and the next carriage belongs to one of the previous carriage partition coordinate sequences. The carriage partition coordinate sequence allows the system to better identify the specific location of each carriage, thus facilitating the subsequent loading of the target carriage.

[0111] Specifically, the loading balance module 3 can be monitored by adding weighing sensors or other equipment, or it can be calculated based on the sum of the weights loaded each time.

[0112] This invention utilizes the loading balancing module 3 to intelligently adjust the landing point, ensuring that materials are evenly distributed within the carriage, avoiding the risk of uneven loading, and improving the utilization rate of carriage space and transportation safety.

[0113] In this embodiment of the invention, the communication coordination module 5 is used to ensure unimpeded communication between modules, thereby improving the overall response speed and stability of the system.

[0114] Example 2

[0115] like Figure 2 As shown, a precision loading control system integrating a grab bucket crane and a weighing system includes a weighing sensor module 1, a bucket number calculation module 6, a drive module 7, a total quantity control module 4, a grab bucket positioning module 2, a motion control module 8, a loading balancing module 3, a safety early warning module 9, and a communication coordination module 5.

[0116] The weighing sensor module 1 is located inside the grab bucket of the grab crane and is used to collect the actual weight W of the material in the grab bucket in real time each time it is fed. a By collecting actual weight data in real time, the weight of each feeding can be accurately determined, providing an accurate basis for subsequent calculations and control, and effectively reducing the total loading deviation caused by weight errors. The bucket number calculation module 6 is used to perform target loading setting, initial bucket number calculation, dynamic density update, and remaining bucket number prediction. It dynamically updates the material density and predicts the remaining bucket number, overcoming the impact of material density fluctuations, significantly improving the accuracy of the total loading, and reducing the risk of overloading and underloading. The specific steps are as follows:

[0117] Set the target loading capacity W of the carriage t and the calibrated volume V of the grab bucket g ;

[0118] According to the formula The initial number of feeding hoppers n0 is calculated, where ρ0 is the standard material density;

[0119] Update the remaining loading quantity W after each feeding. r =W t -∑W a ;

[0120] According to the formula The measured density ρ of the material was calculated. a and in combination with formula The remaining number of bushels n is calculated. s and the remaining number of dou (a unit of volume) n s Passed to driver module 7.

[0121] Furthermore, the hopper count calculation module 6 performs a hopper count pre-verification before the initial feeding. Through pre-verification and manual confirmation, the rationality of the initial hopper count is ensured, further improving the accuracy and safety of loading. Specifically:

[0122] The density fluctuation range ρ was calculated based on historical loading data. min- ρ max ;

[0123] safe interval of bucket number

[0124] The initial feeding bucket number n0 is compared with the safe interval of bucket number n safe , and if the initial feeding bucket number n0 exceeds the safe interval of bucket number n safe , an artificial confirmation process is triggered.

[0125] The driving module 7 is used to receive the bucket number instruction and drive and adjust the grab bucket crane to perform the feeding action, accurately perform the feeding action, ensure the accuracy of each feeding, and improve the efficiency of the loading operation.

[0126] The total amount control module 4 is used to send a stop instruction to the driving module 7 when W r ≤0, to realize accurate stopping, ensure that the total loading amount meets the target requirement, and avoid overloading or underloading.

[0127] The grab bucket positioning module 2 is internally provided with a GNSS positioning unit, an inclination sensor, and a wind speed sensor. The grab bucket positioning module 2 is used to obtain the spatial coordinates (X g , Y g , Z g ) of the grab bucket and the swing angle θ through the GNSS positioning unit and the inclination sensor, and is also used to detect the real-time wind speed using the wind speed sensor and upload the real-time wind speed to the driving module 7. When the real-time wind speed F w >8m / s, the preset reference speed v r is lowered to 80% through the driving module 7. The position and attitude information of the grab bucket is accurately obtained to provide accurate data for trajectory correction; the introduction of the wind speed sensor enables the system to automatically adjust the speed in bad weather, improving the operation safety and stability.

[0128] Optionally, the GNSS positioning unit, the inclination sensor, and the wind speed sensor can adopt the structures in the prior art, and no specific improvement or limitation is made to the structures of the GNSS positioning unit, the inclination sensor, and the wind speed sensor.

[0129] The motion control module 8 is used to generate a grab bucket braking instruction according to the drop point prediction deviation η, and output an angle correction amount Δθ, a speed adjustment value v adj , and a height compensation value H c . The driving module 7 is used to drive the grab bucket crane to perform the trajectory correction action, correct the grab bucket trajectory in real time, ensure that the material is accurately dropped to the target drop point, and improve the drop point accuracy and operation efficiency. Specifically:

[0130] Obtain the carriage partition coordinate sequence {(X1,Y1,Z1),(X2,Y2,Z2),...,(X n ,Y n Z n At the same time, obtain the carriage coordinates (X) of the current target landing point. i ,Y i Z i );

[0131] According to the formula The horizontal deviation D was calculated. h ;

[0132] According to the formula η=D h ×sinθ+|Z g -Z i The predicted landing point deviation η is calculated.

[0133] Preset maximum allowable landing point deviation η max And compare the landing point prediction deviation η with the preset maximum allowable landing point deviation η max Compare the results; if η > η max If the angle correction Δθ is calculated according to the formula Δθ=k·η, the grab bucket braking command is generated to the drive module 7, and the drive module 7 adjusts the grab bucket swing angle according to the angle correction Δθ, where k is the correction coefficient.

[0134] According to the formula The calculated speed regulation value v adj The drive module 7 adjusts the speed value v adj Adjust the crane's moving speed, where kv is the speed attenuation coefficient and vr is the preset reference speed of the grab crane;

[0135] According to formula H c =Z i +k z ·|Z g -Z i The height compensation value H is calculated. c The drive module 7 calculates the height compensation value H. c Adjust the grab release height, where k z This is the height compensation coefficient.

[0136] Safety early warning module 9 is used to implement a multi-level risk prevention and control strategy. Through multi-level early warning and prevention measures, it effectively reduces safety risks during operations and ensures the safety of personnel and equipment. Specifically:

[0137] Level 1 Warning: When the real-time wind speed F w When the speed is greater than 10 m / s, an audible and visual alarm will be triggered;

[0138] Secondary braking: preset the grab crane wire tension threshold T max When the grab crane wire tension T s > 0.95T max , the grab crane is forced to hover;

[0139] Tertiary power-off: preset the grab crane wire structural stress threshold σ th When the grab crane wire structural stress σ th > σ , the main power is cut off and the grab crane is locked.

[0140] In addition, when the safety warning module 9 activates the tertiary power-off risk prevention strategy, the following steps are performed:

[0141] Signal is transmitted to the driving module 7 to start the emergency self-locking device to fix the grab position;

[0142] Signal is transmitted to the grab positioning module 2 to record the hovering coordinates (X e , Y e , Z e ) at this time using the GNSS positioning unit inside the grab positioning module 2;

[0143] Record the instantaneous values of wind speed data, grab crane wire tension data, and grab crane wire structural stress at this time.

[0144] Optionally, the grab crane wire tension can be converted into a change in the angle of the pulley by a three-pulley assembly, and then converted into a measurable line voltage signal by a vibration assembly and an electromagnetic conversion assembly. Finally, through rectification, energy storage circuit and calculation module, real-time monitoring of tension is realized. For specific details, refer to the tension detection device and tension detection method of the prior art CN120445503A. When the steel wire rope passes through the three-pulley assembly, the change in its tension will directly cause the angle between the pulleys to change. For example, when the steel wire rope tension increases, the angle between the pulleys will increase accordingly; conversely, it will decrease. This mechanical deformation provides a basis for subsequent signal conversion. The vibration assembly converts the mechanical displacement caused by the change in the angle of the pulley into a vibration signal. The electromagnetic conversion assembly (such as the relative motion of the coil and the magnet) further converts the vibration signal into a line voltage signal. The size of the line voltage is proportional to the tension of the steel wire rope, thereby achieving indirect measurement of tension to electrical signal. Through the rectification and energy storage circuit, the line voltage generated by the electromagnetic conversion assembly is rectified and stored, without the need for an external power supply to maintain operation. The wireless transmission module transmits the measured line voltage signal to the calculation and data processing module, and finally calculates the dynamic tension value of the steel wire rope through the algorithm.

[0145] Optionally, the stress of the grab crane steel wire rope structure can be directly measured by a steel wire rope tension sensor. The monitoring principle is that the sensor is directly connected in series to one end of the steel wire rope. The tension of the steel wire rope directly acts on the sensor, causing the elastic body inside the sensor to deform. The strain gauge attached to the elastic body detects the deformation and outputs an electrical signal. The steel wire rope tension sensor: usually has S-shaped, spoke-type structures, one end is connected to the fixed end of the steel wire rope, and the other end is connected to the drum or the lifting device. It is usually installed at the fixed end of the steel wire rope, such as at the connection of the upper crossbeam of the grab bucket. The steel wire rope tension sensor directly bears the entire tension, and the measurement accuracy is the highest.

[0146] The loading balancing module 3 is used for monitoring the cumulative weight W of each subzone of the car si , calculating a loading balancing index λ, and switching the target drop point to the lowest load subzone. By intelligently adjusting the drop point, the material is evenly distributed in the car, avoiding the risk of unbalanced loading and improving the utilization rate of car space and transportation safety. Specifically:

[0147] The cumulative weight W of each subzone of the car is monitored in real time s1 ,W s2 ,...,W sm ;

[0148] The loading balancing index λ is calculated according to the formula ;

[0149] The preset loading balancing index threshold λ th , and the loading balancing index λ is compared with the loading balancing index threshold λ th . If λ > λ th , the drop point coordinate sequence is re-planned so that the subsequent material is preferentially placed in the lowest load subzone.

[0150] The communication coordination module 5 is used for establishing a high-speed data channel between the weighing sensor module 1, the bucket number calculation module 6, the grab bucket positioning module 2, the motion control module 8, the loading balancing module 3, the total quantity control module 4, the safety warning module 9, and the driving module 7, to realize real-time instruction transmission. The communication coordination module 5 adopts double-channel redundant transmission to ensure smooth communication between modules, improve the overall response speed and stability of the system, and further enhance the reliability of the data to prevent system paralysis caused by communication failure.

[0151] Specifically:

[0152] The main channel synchronously transmits the spatial coordinates (X g , Y g , Z g ) of the grab bucket, the swing angle θ, and the drop point prediction deviation η at a frequency of 100 Hz;

[0153] Backup channel transmits weighing data and safety warning signal at 50Hz frequency;

[0154] Switch to backup channel automatically when main channel delay > 20ms.

[0155] The embodiment of the present application realizes real-time, reliability and low maintenance: the main channel transmits at 100Hz to meet the dynamic control requirements of the grab (such as swing suppression and landing point correction). The backup channel seamlessly takes over when the main channel fails, ensuring that safety warnings and weighing data are not lost. The automatic recovery mechanism reduces manual intervention and improves system availability to more than 99.9%, which can significantly improve the communication robustness of the grab crane in complex industrial scenarios, balancing high performance and safety

[0156] When the backup channel is activated, the communication coordination module 5 performs the following steps:

[0157] Start the data compression engine to compress the spatial coordinates (X g ,Y g ,Z g ) of the grab using difference encoding.

[0158] Run-length encoding is used to compress the weighing data.

[0159] When the compression ratio is greater than or equal to 50%, transmit at 50Hz; when the compression ratio is less than 50%, reduce the frequency to 25Hz.

[0160] Specifically, the continuity of the grab movement is used to difference encode the three-dimensional coordinates (X g ,Y g ,Z g ): record the initial coordinates as the reference point. For subsequent coordinate points, only the difference (Δx, Δy, Δz) from the previous point is stored. If the difference is close to zero (e.g. change < threshold), a short code (e.g. 1 byte) can be used to represent "no change", thereby reducing redundant data.

[0161] Specifically, the continuous repeated values of the weighing data are compressed. The weighing data sequence is traversed, the length of the continuous same value (run) is counted, and the original data is replaced with (value, run length). For non-repeated values, directly store or mark as a single-point run, thereby significantly reducing the data amount.

[0162] The embodiment of the present application dynamically switches the transmission frequency according to the real-time compression ratio. When the compression ratio is greater than or equal to 50%, maintain 50Hz high-frequency transmission, which can ensure low delay. When the compression ratio is less than 50%, reduce the frequency to 25Hz, which can save bandwidth.

[0163] Embodiment 3

[0164] In combination Figure 3 , Figure 3It is a grab bucket crane loading control method flow chart provided by the application. The grab bucket crane loading control method of the embodiment is applied to the grab bucket crane loading control system of embodiment 1 or embodiment 2.

[0165] First, the target loading amount W of the carriage is input t and the calibrated volume V of the grab bucket is input g At this time, the initial number of buckets n0 is calculated by the bucket number calculation module according to the formula At the same time, the bucket number pre-check is performed by the bucket number calculation module:

[0166] According to the historical loading data, the density fluctuation range ρ min -ρ max is calculated

[0167] The bucket number safety interval n safe is generated

[0168] The initial number of buckets n0 is compared with the bucket number safety interval n safe If the initial number of buckets n0 exceeds the bucket number safety interval n safe , the manual confirmation process is triggered.

[0169] Secondly, the loading control operation is performed, and the actual weight W of the material in the grab bucket is collected in real time by the weighing sensor module a The spatial coordinates (X g , Y g , Z g ) and the swing angle θ of the grab bucket are obtained by the GNSS positioning unit and the inclination sensor inside the grab bucket positioning module, and the real-time wind speed F w is detected by the wind speed sensor inside the grab bucket positioning module.

[0170] In this step, when applied to the grab bucket crane loading control system of embodiment 2, the safety warning module is required to monitor the wind speed, the steel wire rope tension of the grab bucket crane, and the structural stress of the steel wire rope of the grab bucket crane in real time.

[0171] Thirdly, the loading operation is performed, and the remaining amount to be loaded W r is updated by the bucket number calculation module after each feeding W t = W a , and the measured density ρ a of this feeding is calculated according to the formula .

[0172] Simultaneously, the landing point prediction deviation η is calculated by the motion control module:

[0173] The carriage partition coordinate sequence {(X1, Y1, Z1), (X2, Y2, Z2),..., (Xn ,Y n ,Z n ) of the current target drop point are obtained simultaneously; i ,Y i ,Z i );

[0174] The horizontal deviation D h is calculated according to the formula

[0175] The drop point prediction deviation η is calculated according to the formula η = D h × sin θ + |Z g -Z i |.

[0176] Meanwhile, the maximum allowed drop point deviation η max is preset, and the drop point prediction deviation η is compared with the maximum allowed drop point deviation η max . If η > η max , a grab brake command is generated to the driving module, the angle correction amount Δθ is calculated according to the formula Δθ = k·η, the driving module adjusts the swing angle of the grab according to the angle correction amount Δθ, the speed adjustment value v adj is calculated according to the formula , the driving module adjusts the crane moving speed according to the speed adjustment value v adj , the height compensation value H c is calculated according to the formula H i = Z z +k g ·|Z i -Z c |, and the driving module corrects the release height of the grab according to the height compensation value H c , thereby completing the adjustment operation on the grab trajectory.

[0177] The GNSS positioning unit and the inclination sensor are integrated in the grab positioning module to accurately obtain the spatial coordinates and swing angle of the grab in real time, and the motion control module calculates the drop point prediction deviation using these data. When the deviation exceeds the preset threshold, the angle correction amount, the speed adjustment value and the height compensation value are generated and output to the driving module in real time to dynamically correct the grab trajectory, ensuring that the material is accurately dropped into the target drop point. In addition, the introduction of the wind speed sensor enables the system to automatically reduce the preset reference speed of the crane to 80% when the real-time wind speed is greater than 8 m / s, thereby significantly reducing the influence of wind load on the stability of the grab and the drop point accuracy, and improving the operation safety and control stability in bad weather.

[0178] In the fifth step, the cumulative weight W s1 of each partition of the car body is monitored in real time by the car loading balancing module.​s2 ..., W sm , and according to the formula The loading balance index λ is calculated. At the same time, the loading balance index threshold λ th is preset, and the loading balance index λ is compared with the loading balance index threshold λ th If λ > λ th , the landing point coordinate sequence is re-planned, and the subsequent material is preferentially put into the lowest load partition.

[0179] The cumulative weight of each partition of the car is monitored in real time by the loading balance module, and the loading balance index is calculated. When the index exceeds the preset threshold, it indicates that the material distribution in the car is not balanced, and the system will automatically re-plan the landing point coordinate sequence, and the subsequent material will be preferentially put into the lowest load partition. By using this intelligent landing point dynamic adjustment strategy, the problem of local overloading or underloading of materials in the car is effectively avoided, the car space utilization and loading uniformity are improved, the transportation risk caused by uneven loading is reduced, and the workload of subsequent flat cars is reduced.

[0180] Step 6, at the same time, the remaining bucket number n is calculated by the bucket number calculation module according to the formula s , and the remaining bucket number n s is transmitted to the driving module, and the driving module is used to continue to control the grab bucket crane to load the car until the total amount control module monitors W r ≤0, and sends a stop command to the driving module to control the grab bucket crane to stop loading.

[0181] By setting a weighing sensor module inside the grab bucket, real-time actual weight data of each material is collected, and the grab bucket calibration volume is used by the bucket number calculation module to dynamically update the measured density of the material, and the remaining bucket number is recalculated accordingly. By using a closed-loop control mechanism based on actual material weight and dynamically updated density, the impact of material density fluctuations is effectively overcome, and the cumulative error caused by inaccurate standard density preset is greatly reduced. Finally, the total amount control module accurately stops when the target loading amount is reached, achieving high-precision control of the total loading amount and reducing the risk of overloading and underloading.

[0182] For example:

[0183] First, the car target loading amount W t and the grab bucket calibration volume V g are input, the car target loading amount is set to 60 tons and the grab bucket calibration volume is set to 8 m3. At this time, the bucket number calculation module calculates the remaining bucket number n The initial feeding hopper number n0 is calculated, the standard material density is 1.5 tons / m3, and the initial feeding hopper number is calculated as 5, and the hopper number pre-checking is performed by using the hopper number calculation module:

[0184] The density fluctuation range p is calculated according to historical loading data min - p max ;

[0185] The hopper number safety interval is generated

[0186] The initial feeding hopper number n0 is compared with the hopper number safety interval n safe , if the initial feeding hopper number n0 exceeds the hopper number safety interval n safe , the confirmation process is triggered.

[0187] Second step, then perform the loading control operation, the actual weight W a of the material in the grab bucket is collected in real time by using the weighing sensor module each time the material is fed, assuming that the actual weight W a of the material in the grab bucket is updated after the first feeding is 11.8 tons. And the spatial coordinates (X g , Y g , Z g ) and swing angle θ of the grab bucket are obtained by using the GNSS positioning unit and the inclination sensor inside the grab bucket positioning module, and the real-time wind speed F w is detected by using the wind speed sensor inside the grab bucket positioning module.

[0188] Third step, then perform the loading operation, the remaining amount to be loaded W r is updated by the hopper number calculation module after each feeding W t = W a , and the measured density p a of this feeding is calculated according to the formula , the remaining amount to be loaded is calculated as 60-11.8=48.2 tons, and the measured density p a =1.475 tons / m 3 is updated.

[0189] Fourth step, at the same time, the landing point prediction deviation η is calculated by using the motion control module:

[0190] The car compartment coordinate sequence {(X1, Y1, Z1), (X2, Y2, Z2),..., (X n , Y n , Z n )} is obtained, and the car compartment coordinates (X i , Y i , Z i ) of the current target landing point are obtained;

[0191] According to the formula The horizontal deviation D is calculated h ;

[0192] According to the formula The landing point prediction deviation η is calculated.

[0193] At the same time, the maximum allowable landing point deviation η max is preset, and the landing point prediction deviation η is compared with the preset maximum allowable landing point deviation η max If η > η max , a grab brake command is generated to the drive module, and the angle correction amount Δθ is calculated according to the formula Δθ = k·η. The drive module adjusts the swing angle of the grab according to the angle correction amount Δθ. And according to the formula The speed adjustment value v adj is calculated adj , and the drive module adjusts the crane moving speed according to the speed adjustment value v adj . At the same time, according to the formula H c = Z i +k z ·|Z g -Z i |The height compensation value H c is calculated c , and the drive module corrects the release height of the grab according to the height compensation value H c , thereby completing the adjustment operation of the grab trajectory.

[0194] Through the grab positioning module integrated with GNSS positioning unit and inclination sensor, the spatial coordinates and swing angle of the grab are accurately obtained in real time, and through the motion control module, the landing point prediction deviation is calculated using these data. When the deviation exceeds the preset threshold, the angle correction amount, the speed adjustment value and the height compensation value are generated and output to the drive module in real time to dynamically correct the grab trajectory, ensure the accurate delivery of the material to the target landing point. In addition, through the introduction of the wind speed sensor, the system can automatically reduce the crane preset reference speed to 80% when the real-time wind speed is greater than 8m / s, thereby significantly reducing the influence of wind load on the stability of the grab and the landing point accuracy, and improving the operation safety and control stability in bad weather.

[0195] Step 5, through the car equalization module, the cumulative weight W s1 , W s2 ,..., W sm of each partition of the car is monitored in real time, and the loading balance index λ is calculated according to the formula At the same time, the loading balance index threshold λ th is preset, and the loading balance index λ is compared with the loading balance index threshold λ th If λ > λ th , the landing point coordinate sequence is re-planned, and the subsequent material is preferentially delivered to the lowest load partition.

[0196] The loading balance module is used for monitoring the cumulative weight of each subarea of the car in real time, and a loading balance index is calculated. When the index exceeds a preset threshold, it indicates that the material distribution in the car is not balanced. The system will automatically re-plan the drop point coordinate sequence, and the subsequent material will be preferentially put into the subarea with the lowest load. By using this intelligent drop point dynamic adjustment strategy, the problem of local overloading or underloading of the material in the car is effectively avoided, the space utilization and loading uniformity of the car are improved, the transportation risk caused by uneven loading is reduced, and the workload of the subsequent flat car is reduced.

[0197] In the sixth step, the remaining bucket number n is calculated by the bucket number calculation module according to the formula The remaining bucket number n is calculated by the bucket number calculation module according to the formula s The remaining bucket number n is calculated by the bucket number calculation module according to the formula s The remaining bucket number n is calculated by the bucket number calculation module according to the formula r The remaining bucket number n is calculated by the bucket number calculation module according to the formula

[0198] Although some specific embodiments of the present application have been described in detail through examples, those skilled in the art should understand that the above examples are only for illustration, and are not intended to limit the scope of the present application. Those skilled in the art should understand that the above embodiments can be modified without departing from the scope and spirit of the present application. The scope of the present application is defined by the appended claims.

Claims

1. A loading control system for a grab crane, characterized in that, include: The system includes a weighing sensor module, a bucket capacity calculation module, a total quantity control module, a grab bucket positioning module, a motion control module, a loading balancing module, a communication coordination module, and a drive module. The weighing sensor module is coupled to the bucket number calculation module through the communication coordination module and is located inside the grab bucket of the grab crane. It is used to collect the actual weight W of the material in the grab bucket in real time for each feeding. a Send to the number calculation module; The hopper count calculation module is coupled to the weighing sensor module, the total quantity control module, and the drive module through the communication coordination module. It is used to perform target loading quantity setting, initial hopper count calculation, density dynamic updating, remaining loading quantity updating, and remaining hopper count prediction, including: Set the target loading capacity W of the carriage t and the calibrated volume V of the grab bucket g ; According to the formula The initial number of feeding hoppers n0 is calculated, where ρ0 is the standard material density; Update the remaining loading quantity W after each feeding. r =W t -∑W a And send it to the total quantity control module; According to the formula The measured density ρ of the material was calculated. a and in combination with formula The remaining number of bushels n is calculated. s and the remaining number of dou (a unit of volume) n s Passed to the driver module; The drive module is coupled to the bucket number calculation module and the total quantity control module respectively, and is used to receive bucket number instructions and drive and adjust the grab crane to perform feeding actions; The total quantity control module is coupled to the drive module and is used to calculate the remaining amount W to be loaded in the bucket number calculation module. r When ≤0, a stop command is sent to the driver module; The grab positioning module is installed inside the grab of the grab crane and is used to obtain the spatial coordinates (X, Y, Z) of the grab. g ,Y g Z g ) and the swing angle θ, where X g Let Y be the coordinate of the grab bucket in the horizontal direction of the horizontal plane. g Let Z be the coordinate of the grab bucket along the vertical axis in the horizontal plane. g This indicates the coordinates of the grab bucket along the vertical axis. The motion control module is coupled to the drive module and is used to generate a grab bucket braking command based on the landing point prediction deviation η, and output the angle correction amount Δθ and the speed adjustment value v. adj and height compensation value H c The data is sent to the drive module to drive the grab crane to perform trajectory correction actions, including: Obtain the carriage partition coordinate sequence {(X1,Y1,Z1),(X2,Y2,Z2),...,(X n ,Y n Z n At the same time, obtain the carriage coordinates (X) of the current target landing point. i ,Y i Z i ); According to the formula The horizontal deviation D was calculated. h ; According to the formula η=D h ×sinθ+|Z g -Z i The predicted landing point deviation η is calculated. Preset maximum allowable landing point deviation η max And compare the landing point prediction deviation η with the preset maximum allowable landing point deviation η max Compare the results; if η > η max If the angle correction Δθ is calculated according to the formula Δθ=k·η, the grab bucket braking command is generated and sent to the drive module. The drive module adjusts the grab bucket swing angle according to the angle correction Δθ, where k is the correction coefficient. According to the formula The calculated speed regulation value v adj The drive module adjusts the speed value v. adj Adjust the crane's moving speed, where k v v is the velocity decay coefficient. r Preset a reference speed for the grab crane; According to formula H c =Z i +k z ·|Z g -Z i |Calculate the height compensation value H c , where k z This is the height compensation coefficient; The height compensation value H c The data is sent to the driver module, which then calculates the height compensation value H. c Adjust the grab release height; The loading balancing module is coupled to the drive module and is used to monitor the cumulative weight W of each section of the carriage. si Calculate the load balancing index λ and switch the target landing point to the low-load partition, including: Real-time monitoring of the cumulative weight W in each compartment of the carriage s1 W s2 ,...,W sm ; According to the formula The load balancing index λ is calculated. Preset load balancing index threshold λ th And compare the load balancing index λ with the load balancing index threshold λ th Comparing them, if λ > λ th If so, the landing point coordinate sequence is replanned, and the target landing point is switched to the low-load partition; The communication coordination module is coupled to the weighing sensor module, bucket count calculation module, total quantity control module, grab bucket positioning module, motion control module, loading balancing module, and drive module, respectively, to establish a high-speed data channel between the weighing sensor module, bucket count calculation module, total quantity control module, grab bucket positioning module, motion control module, loading balancing module, and drive module, so as to realize real-time command transmission.

2. The grab crane loading control system according to claim 1, characterized in that, The grab positioning module is internally equipped with a GNSS positioning unit and a tilt sensor, and obtains the spatial coordinates (X, Y) of the grab through the GNSS positioning unit. g ,Y g Z g The tilt sensor is used to obtain the swing angle θ of the grab bucket.

3. The grab crane loading control system according to claim 2, characterized in that, The grab positioning module includes a wind speed sensor, which detects real-time wind speed and sends the real-time wind speed to the drive module. When the real-time wind speed F... w When the speed is greater than 8 m / s, the preset reference speed v of the grab crane is controlled by the drive module. r Reduced to 80%.

4. The grab crane loading control system according to claim 3, characterized in that, It also includes a safety early warning module that is coupled to the grab positioning module and the drive module respectively through the communication coordination module, for implementing a three-level risk prevention and control strategy, including: Level 1 Warning: When the real-time wind speed F w When the speed is greater than 10 m / s, an audible and visual alarm will be triggered; Secondary braking: Preset wire rope tension threshold T for grab crane max When the tension T of the wire rope of the grab crane s >0.95T max At that time, the grab crane was forcibly stopped. Level 3 Power Failure: Preset stress threshold σ for the wire rope structure of the grab crane. t h, when the structural stress σ > σ of the grab crane wire rope is detected th Cut off the main power supply and lock the grab crane.

5. The grab crane loading control system according to claim 4, characterized in that, The security early warning module, after activating the three-level risk prevention and control strategy, includes: A safety warning signal is sent to the drive module, which then activates the emergency self-locking device to fix the grab bucket position. A safety warning signal is sent to the grab positioning module, and the GNSS positioning unit inside the grab positioning module records the hovering coordinates (X). e ,Y e Z e ); Record wind speed, wire rope tension data of grab crane, and instantaneous values ​​of structural stress of grab crane wire rope.

6. The grab crane loading control system according to claim 5, characterized in that, The communication coordination module employs dual-channel redundant transmission, including: The main channel synchronously transmits the spatial coordinates (X) of the grab bucket at a frequency of 100Hz. g ,Y g Z g ), swing angle θ and landing point prediction deviation η; The backup channel transmits weighing data and safety warning signals at a frequency of 50Hz. Automatically switch to backup channel when the main channel delay is greater than 20ms.

7. The grab crane loading control system according to claim 6, characterized in that, When the backup channel is activated, the communication coordination module performs the following steps: The data compression engine is activated to compress the spatial coordinates (X) of the grab bucket. g ,Y g Z g Differential encoding compression is used; Run-length encoding compression is used for re-encoded data; When the compression ratio is greater than or equal to 50%, the transmission frequency is maintained at 50Hz; when the compression ratio is less than 50%, the frequency is reduced to 25Hz.

8. The grab crane loading control system according to claim 1, characterized in that, The hopper number calculation module performs a hopper number pre-verification before the first feeding, including: The density fluctuation range ρ was calculated based on historical loading data. min -ρ max ; Generate a safe range for the number of zodiac signs. The initial feeding hopper number n0 and the hopper number safety range n safe A comparison is performed; if the initial feed hopper number n0 exceeds the safe hopper number range n... safe This triggers the confirmation process.

9. A loading control method for a grab bucket crane, characterized in that, The application of the grab crane loading control system according to any one of claims 1 to 8 includes the following steps: Input the target loading capacity W of the carriage t and the calibrated volume V of the grab bucket g At this time, the Dou Shu calculation module calculates according to the formula. The initial number of feeding hoppers n0 is calculated; Loading control operations include using a weighing sensor module to collect the actual weight W of the material in the grab bucket during each feeding operation in real time. a And obtain the spatial coordinates (X) of the grab. g ,Y g Z g and the swing angle θ; During the loading operation, the remaining loading quantity W is updated via the bucket number calculation module after each feeding. r =W t -ΣW a And according to the formula Calculate the measured density ρ of the material being fed in this experiment. a ; The landing point prediction deviation η is calculated using the motion control module. Obtain the carriage partition coordinate sequence {(X1,Y1,Z1),(X2,Y2,Z2),...,(X n ,Y n Z n At the same time, obtain the carriage coordinates (X) of the current target landing point. i ,Y i Z i ); According to the formula The horizontal deviation D was calculated. h ; According to the formula η=D h ×sinθ+|Z g -Z i The predicted landing point deviation η is calculated. Preset maximum allowable landing point deviation η max And compare the landing point prediction deviation η with the preset maximum allowable landing point deviation η max Compare the results; if η > η max If this occurs, a grab braking command is generated and sent to the drive module. The angle correction Δθ is calculated using the formula Δθ=k·η. The drive module then adjusts the grab swing angle based on the angle correction Δθ. And according to the formula... The calculated speed regulation value v adj The drive module adjusts the speed value v. adj Adjust the crane's moving speed; simultaneously, according to formula H... c =Z i +k z ·|Z g -Z i |Calculate the height compensation value H c The drive module is based on the height compensation value H c Adjust the grab release height; The loading balance module monitors the cumulative weight W of each section of the car body in real time. s1 W s2 ,...,W sm And according to the formula The load balancing index λ is calculated, and the load balancing index threshold λ is preset. th And compare the load balancing index λ with the load balancing index threshold λ th Compare the results; if λ > λ th If so, the landing point coordinate sequence is replanned, and the target landing point is switched to the low-load partition; The Dou Shu calculation module calculates based on the formula. The remaining number of bushels n is calculated. s and the remaining number of dou (a unit of volume) n s The signal is transmitted to the drive module, which then continues to control the grab crane to perform loading operations until the total quantity control module detects W. r When the value is ≤0, a stop command is sent to the drive module, which then controls the grab crane to stop loading.

10. The loading control method for a grab crane according to claim 9, characterized in that, During loading control operations, real-time monitoring is conducted on wind speed, the tension of the grab crane's wire rope, and the structural stress of the grab crane's wire rope, including: When the real-time wind speed F w When the speed is greater than 10 m / s, an audible and visual alarm will be triggered; Preset wire rope tension threshold T for grab crane max When the tension T of the wire rope of the grab crane s >0.95T max At that time, the grab crane was forcibly stopped. Preset stress threshold σ for wire rope structure of grab crane th When the structural stress σ of the grab crane wire rope is detected to be greater than σ, th Cut off the main power supply and lock the grab crane.

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