An intelligent gateway for preventing overload of lifting equipment

Abstract

The invention discloses an anti-overload intelligent gateway for lifting equipment, comprising an MCU, a top impact detection switch, an inclination sensor, a transmitter, a 4G module, a 485 communication module, a digital input and output module, an analog input and output module, a display screen and a key module connected to the MCU, and a weighing sensor connected to the transmitter, which realizes multiple functions such as anti-top impact limit, oblique pull limit, overload limit and the like, and also has the functions of data recording and digital maintenance early warning, effectively reducing unexpected shutdown accidents, and is suitable for electric hoists and single- and double-beam bridge cranes.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent control of lifting equipment, and more particularly to an anti-overload intelligent gateway for lifting equipment. Background Art

[0002] At present, during the use of lifting equipment, due to the different levels of operators, problems such as oblique pulling, oblique lifting, and top collision often occur. In order to avoid the above problems, heavy hammer limiter, overload limiter, anti-top collision limiter, anti-oblique pulling limiter, two-in-one limiter, three-in-one limiter and other equipment have been studied, but the existing equipment has relatively single functions and only plays a certain role.

[0003] Therefore, how to provide a multifunctional intelligent gateway is a problem that technical personnel in this field need to solve urgently. Summary of the invention

[0004] In view of this, the present invention provides an anti-overload intelligent gateway for lifting equipment, which has the functions of anti-top impact, inclined limit, and overload limit. It also has the functions of data recording and digital maintenance and early warning, which is convenient for equipment management and can be used for electric hoists and single- and double-beam bridge cranes.

[0005] In order to achieve the above object, the present invention adopts the following technical solution:

[0006] An anti-overload intelligent gateway for lifting equipment, comprising: an MCU, a top impact detection switch, an inclination sensor, a weighing sensor, a transmitter, a communication module and a key module, wherein the top impact detection switch, the inclination sensor, the transmitter, the communication module and the key module are all connected to the MCU, and the weighing sensor is connected to the transmitter;

[0007] The top impact detection switch is used for hook top impact detection;

[0008] The inclination sensor is used to detect the inclined pulling angle of the hoisted object;

[0009] The weighing sensor is used to detect the weight of the equipment load;

[0010] The transmitter is used to amplify the weight signal;

[0011] The communication module is used to communicate with the external control device and the cloud platform;

[0012] The MCU is used for data analysis and processing;

[0013] The button module is used to set working parameters.

[0014] Furthermore, it also includes a digital input and output module and an analog input and output module, and both the digital input and output module and the analog input and output module are connected to the MCU;

[0015] The digital input and output module is used to collect and control the switch status of external devices;

[0016] The analog quantity input and output module is used to collect and control the analog quantity of the external device.

[0017] Furthermore, it also includes an indicator light and a buzzer, and the indicator light and the buzzer are both connected to the MCU;

[0018] The buzzer is used to sound an alarm under abnormal working conditions;

[0019] The indicator light is used to light up under abnormal working conditions.

[0020] Furthermore, it also includes a display screen, which is connected to the MCU and is used to display parameters in real time.

[0021] Furthermore, it also includes a data storage device, which is connected to the MCU and is used to store data.

[0022] Further, the communication module includes a 4G module and a 485 communication module, and both the 4G module and the 485 communication module are connected to the MCU;

[0023] The 4G module is used to communicate with the cloud platform;

[0024] The 485 communication module is used to communicate with external control equipment.

[0025] Furthermore, the indicator light includes a warning indicator light and an alarm indicator light.

[0026] Furthermore, a power supply module is included to provide power to the entire device.

[0027] It can be seen from the above technical solution that compared with the prior art, the present invention discloses an anti-overload intelligent gateway for lifting equipment, which realizes multiple functions such as anti-top limit, inclined limit, overload limit, etc., effectively reduces unexpected shutdown accidents, and is suitable for electric hoists and single- and double-beam bridge cranes. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0029] Figure 1 The accompanying drawing is a block diagram of the structure principle of the intelligent gateway provided by the present invention.

[0030] Figure 2 The accompanying drawing is a specific circuit diagram of the MCU provided by the present invention.

[0031] Figure 3 The accompanying drawings are specific circuit diagrams of the display screen and indicator light provided by the present invention.

[0032] Figure 4 The accompanying drawing is a specific circuit diagram of the inclination sensor provided by the present invention.

[0033] Figure 5 The accompanying drawing is a specific circuit diagram of the 485 communication module provided by the present invention.

[0034] Figure 6 The accompanying drawing is a specific circuit diagram of the 4G module provided by the present invention.

[0035] Figure 7 The accompanying drawing is a specific circuit diagram of the key module provided by the present invention.

[0036] Figure 8 The accompanying drawing is a specific circuit diagram of the buzzer provided by the present invention.

[0037] Fig. 9 The accompanying drawing is a specific circuit diagram of the power module provided by the present invention.

[0038] Fig.10 The accompanying drawing shows the analog input and output module provided by the present invention.

[0039] Fig.11 The accompanying drawing shows the digital input and output module provided by the present invention.

[0040] Fig.12 The accompanying drawing is a specific circuit diagram of the relay provided by the present invention. DETAILED DESCRIPTION

[0041] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. 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 creative work are within the scope of protection of the present invention.

[0042] The embodiment of the present invention discloses an anti-overload intelligent gateway for lifting equipment, such as Figure 1As shown, it includes an MCU, and a top impact detection switch, an inclination sensor, a transmitter, a 4G module, a 485 communication module, a digital input and output module, an analog input and output module, a display screen and a button module connected to the MCU, and a weighing sensor connected to the transmitter.

[0043] Among them, the display screen is a 7-segment digital tube screen, which is used to display real-time parameters, including load weight;

[0044] Top impact detection switch: a limit switch used for hook top impact detection;

[0045] Inclination sensor: detects the inclined angle of the hoisted object;

[0046] Load cell: detects the weight of the equipment load;

[0047] Transmitter: amplifies and conditions the signal output by the weighing sensor and sends it to the MCU for detection;

[0048] Button module: used to set working parameters;

[0049] Buzzer: sounds an alarm under abnormal working conditions;

[0050] Data storage: save user data;

[0051] 4G module: realize data interaction with the cloud platform;

[0052] 485 communication module: read and write the parameters of external control devices, such as PLC or inverter parameters, for data storage, analysis and processing, etc.

[0053] Digital input and output: read the switch quantity of external devices, read the switch status of external devices, judge the working condition of the corresponding equipment, and display it on the display screen to provide a basis for digital inspection.

[0054] Analog input and output: read or control the analog quantity of external devices and output corresponding control signals.

[0055] Power module: used to provide power for the entire device.

[0056] The working principle and working process are:

[0057] 1) Anti-top limit:

[0058] When the hook and the suspended object rise and are about to hit the top, the hook touches the top detection switch baffle, the top limit switch is disconnected, and the MCU detects the corresponding trigger signal, thereby controlling the normally closed relay connected to the MCU to disconnect. At the same time, the buzzer is controlled to sound an alarm and upload the trigger signal data to the cloud platform through the 4G module. After the normally closed relay is disconnected, the hook and the suspended object no longer rise, thereby achieving anti-collision control.

[0059] 2) Anti-slanting limiter:

[0060] The smart gateway is fixed on the wire rope of lifting equipment such as cranes or electric hoists. By detecting the inclination angle of the equipment, the inclined angle between the crane hoisting object and the vertical line of the wire rope can be known.

[0061] The MCU reads the gravity acceleration of the XYZ axis of the inclination sensor in real time, and through the Cartesian-spherical coordinate transformation, the current angle of the hoisted object can be known. When the inclined angle is less than 27 degrees, it means that the equipment is safe; when the inclined angle is between 27-30 degrees, the MCU controls the warning light (yellow light) to light up and controls the buzzer to issue a warning; when the angle is between 31-32 degrees, the MCU controls the alarm light to light up (red light) and controls the buzzer to issue an alarm. If it is detected that this state lasts for more than 5 seconds, the output relay is turned off to achieve the anti-oblique pull effect. When the angle exceeds 32 degrees, the alarm light is controlled to light up, the buzzer issues an alarm, and the output relay is immediately turned off to achieve the anti-oblique pull effect.

[0062] At the same time, during the real-time monitoring process, when it is calculated that the angle change exceeds 3 degrees within the set time, the angle change data is sent to the cloud platform through the 4G module, indicating that the device is operating normally.

[0063] 3) Anti-overload limit: to detect the tension of the wire rope.

[0064] The weighing sensor converts the detected tension into a differential signal of the bridge and sends it to the transmitter for amplification and then to the MCU for ADC conversion, zero point compensation and sensitivity correction to obtain the actual load weight. When the actual load is detected to be less than 0.9 times the rated load, the equipment is safe; when the actual load is between 0.9-1.0 times the rated load, the control warning light is lit and the control buzzer is controlled to issue a warning; when the actual load is between 1.0-1.1 times the rated load, the control alarm light is lit and the control buzzer is controlled to issue an alarm. If this state lasts for more than 5 seconds, the output relay is turned off and the overload protection limit is reached. When the actual load exceeds 1.1 times the rated load, an alarm is immediately issued and the output relay is turned off to reach the overload protection limit.

[0065] At the same time, during the real-time monitoring process, when it is calculated that the load change exceeds 0.05 times the rated load within the set time, the load change data is sent to the cloud platform through the 4G module, indicating that the equipment is operating normally.

[0066] The present invention has the following advantages:

[0067] 1. It realizes multiple functions such as anti-top limit, inclined limit, overload limit, etc.

[0068] 2. The 4G module uploads data, alleviating network delays;

[0069] 3. It has the functions of data recording, analysis, early warning, and digital maintenance, which can guide standardized operations and reduce safety hazards.

[0070] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0071] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An anti-overload intelligent gateway for lifting equipment, characterized in that: include: MCU, top impact detection switch, inclination sensor, weighing sensor, transmitter, communication module and key module, the top impact detection switch, the inclination sensor, the transmitter, the communication module and the key module are all connected to the MCU, and the weighing sensor is connected to the transmitter; The top impact detection switch is used for hook top impact detection; The inclination sensor is used to detect the inclined pulling angle of the hoisted object; The weighing sensor is used to detect the weight of the equipment load; The transmitter is used to amplify the weight signal; The communication module is used to communicate with the external control device and the cloud platform; The MCU is used for data analysis and processing; The button module is used to set working parameters; It also includes a digital input and output module and an analog input and output module, and both the digital input and output module and the analog input and output module are connected to the MCU; The digital input and output module is used to collect and control the switch status of external devices; The analog input and output module is used to collect and control the analog quantity of the external device; It also includes an indicator light and a buzzer, both of which are connected to the MCU; The buzzer is used to sound an alarm under abnormal working conditions; The indicator light is used to light up under abnormal working conditions; The communication module includes a 4G module and a 485 communication module, and both the 4G module and the 485 communication module are connected to the MCU; The 4G module is used to communicate with the cloud platform; The 485 communication module is used to communicate with external control equipment; The indicator lights include a warning indicator light and an alarm indicator light; When the hook and the suspended object are about to reach the top, the hook touches the top detection switch baffle, the top limit switch is disconnected, and the MCU detects the corresponding trigger signal, thereby controlling the normally closed relay connected to the MCU to disconnect, and at the same time controlling the buzzer to sound an alarm and upload the trigger signal data to the cloud platform through the 4G module. After the normally closed relay is disconnected, the hook and the suspended object no longer rise, thereby achieving anti-collision control; The MCU reads the gravity acceleration of the XYZ axis of the inclination sensor in real time, and through the Cartesian-spherical coordinate transformation, it can know the current angle of the hoisted object. When the inclined angle is less than 27 degrees, it means that the equipment is safe; when the inclined angle is between 27 and 30 degrees, the MCU controls the early warning indicator to light up and controls the buzzer to issue an early warning; when the angle is between 31 and 32 degrees, the MCU controls the alarm indicator to light up and controls the buzzer to issue an alarm. If it is detected that this state lasts for more than 5 seconds, the output relay is turned off to achieve the anti-oblique pulling effect. When the angle exceeds 32 degrees, the alarm light is controlled to light up, the buzzer is alarmed, and the output relay is immediately turned off to achieve the anti-oblique pulling effect. At the same time, during the real-time monitoring process, when the angle change is calculated to exceed 3 degrees within the set time, the angle change data is sent to the cloud platform through the 4G module, indicating that the device is operating normally; The weighing sensor converts the detected tension into a differential signal of the bridge and sends it to the transmitter for amplification and then to the MCU for ADC conversion, zero point compensation and sensitivity correction to obtain the actual load weight. When the actual load is detected to be less than 0.9 times the rated load, the equipment is safe; when the actual load is between 0.9 and 1.0 times the rated load, the early warning indicator light is controlled to light up and the buzzer is controlled to issue an early warning; when the actual load is between 1.0 and 1.1 times the rated load, the alarm indicator light is controlled to light up and the buzzer is controlled to issue an alarm. If this state lasts for more than 5 seconds, the output relay is turned off to reach the overload protection limit; when the actual load exceeds 1.1 times the rated load, an alarm is immediately issued and the output relay is turned off to reach the overload protection limit. At the same time, during the real-time monitoring process, when it is calculated that the load change exceeds 0.05 times the rated load within the set time, the load change data is sent to the cloud platform through the 4G module, indicating that the equipment is operating normally.

2. The anti-overload intelligent gateway for lifting equipment according to claim 1 is characterized in that: It also includes a display screen, which is connected to the MCU and is used to display parameters in real time.

3. The anti-overload intelligent gateway for lifting equipment according to claim 2 is characterized in that: It also includes a data storage device, which is connected to the MCU and is used to store data.

4. The anti-overload intelligent gateway for lifting equipment according to claim 1 is characterized in that: A power module is also included to provide power to the entire device.

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