Crane maintenance system and crane

Abstract

This invention simplifies the maintenance of cranes that require high-altitude operations. Therefore, a crane maintenance system (100) is provided, comprising: a movable body (40) having a camera mechanism (41) and moving around a crane (20); and a processing unit (50) performing prescribed processing on video image data captured by the camera mechanism (41), wherein the movable body (40) is configured to capture images of multiple parts including the maintenance areas of the crane (20). This reduces the necessity for operators to perform maintenance work on the crane (20) requiring high-altitude operations, thus alleviating the burden of maintenance work.

Description

Technical Field

[0001] This invention relates to a crane maintenance system and a crane. Background Technology

[0002] Construction machinery such as cranes require various maintenance checks for operational safety.

[0003] In particular, the larger the device, such as a tower crane, the higher the safety requirements become (see, for example, Patent Document 1).

[0004] Previous technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2018-162125 Summary of the Invention

[0007] The technical problem to be solved by the invention

[0008] Crane maintenance work often requires working at height with the boom erected, so it's necessary to perform maintenance with the boom lowered. However, lowering the boom requires a relatively large operating space.

[0009] Furthermore, due to this problem, it is sometimes difficult to carry out crane maintenance work on-site.

[0010] The purpose of this invention is to facilitate the maintenance of cranes.

[0011] means for solving technical problems

[0012] This invention provides a crane maintenance system, which has the following features:

[0013] A moving body, equipped with a camera mechanism, moves around a crane with a boom whose pitch angle can be adjusted; and

[0014] The processing unit performs prescribed processing on the video image data captured by the camera mechanism, wherein...

[0015] The moving body photography includes multiple parts of the crane's maintenance area.

[0016] The moving body moves to a shooting position based on the pitch angle of the boom detected by sensors on the crane.

[0017] The processing unit performs the prescribed processing on the video image data of the multiple parts captured by the camera mechanism, thereby enabling maintenance.

[0018] The specified processing includes any one of the following:

[0019] Diagnostic procedures are performed to determine whether any abnormalities have occurred in the maintenance areas of the crane based on the camera image data.

[0020] The crane is created based on multiple camera image data as part of the image data processing.

[0021] Display processing of the three-dimensional model data to the user or of the video images based on the video image data of the multiple parts captured.

[0022] Invention Effects

[0023] According to the present invention, crane maintenance can be easily carried out. Attached Figure Description

[0024] Figure 1 This is a schematic diagram illustrating the crane maintenance system according to embodiments of the present invention.

[0025] Figure 2 It is a block diagram representing the control system of a moving body.

[0026] Figure 3 This is an explanatory diagram showing an example of the configuration of a moving body relative to a crane.

[0027] Figure 4 This is a side view of the crane.

[0028] Figure 5 This is a block diagram representing the control system of a crane.

[0029] Figure 6 It is a block diagram representing the structure of the management server.

[0030] Figure 7 This is a diagram representing an example of information stored in a crane inspection information database.

[0031] Figure 8 This is a diagram representing an example of information stored in a customer information database.

[0032] Figure 9 The front view of the moving body (1), which is an example of a moving body supported by a guide component.

[0033] Figure 10 The following is a side view of a moving body (1), which is an example of a moving body supported by a guide component.

[0034] Figure 11 This is a left view of the moving body supported by the guide components.

[0035] Figure 12It is a top view of the moving body supported by the guide components.

[0036] Figure 13 It is a top view of a slider that allows a moving object to slide along a guide component.

[0037] Figure 14 This is the left view of the slider.

[0038] Figure 15 This is the main view of the slider.

[0039] Figure 16 This is a top view of the moving body in example (2), which is supported by a guide component.

[0040] Figure 17 It is a top view of the body of the moving object with the top surface removed.

[0041] Figure 18 This is the front view with the side walls of the fuselage cut off.

[0042] Figure 19 It is a top view of the moving body supported by the guide components.

[0043] Figure 20 This is a left view of the moving body supported by the guide components.

[0044] Figure 21 This is a top view showing the other support structures of the guide component. Detailed Implementation

[0045] [Overview of the Crane Maintenance System]

[0046] Figure 1 This is a schematic diagram illustrating the crane maintenance system according to embodiments of the present invention. (See diagram below.) Figure 1 As shown, the maintenance system 100 includes a first movable body 40A and a second movable body 40B that move around the crane 20, a crane terminal 30, an information terminal 60 and 70, and a management server 50, which are processing units that perform prescribed processing on the information acquired by each movable body 40A and 40B.

[0047] The management server 50 is connected to the general public line network, etc. (i.e., network 130).

[0048] In network 130, in addition to the management server 50, base stations 120 and 150, as well as information terminals 60 and 70, are also connected. The management server 50 can transmit and receive data with these nodes connected to network 130 (i.e., base stations 120 and 150, mobile devices 40A and 40B, and multiple terminals 30, 60, and 70).

[0049] Base station 120 is a satellite communication line base station capable of transmitting and receiving radio waves via satellite 110, and base station 150 is a so-called mobile phone communication line base station.

[0050] If base stations 120 and 150 receive various data from mobile devices 40A and 40B or crane terminal 30, they will send the data to management server 50 via network 130.

[0051] The crane 20 has various sensors that detect the status of its various parts and a crane terminal 30 that can communicate with the network 130.

[0052] The controller 31 (reference) of the crane terminal 30 Figure 5 (via the first transmitting unit 351 and the second transmitting unit 352 (see reference)) Figure 5 The information detected by various sensors (hereinafter referred to as sensor information) will be transmitted to base stations 120 and 150. Furthermore, the crane terminal 30 can also transmit information via the first receiving unit 361 and the second receiving unit 362 (see reference 360). Figure 5 ) Receive the prescribed information.

[0053] The management server 50 is connected to an inspection information database 140 and a customer information database 160. The management server 50 includes a control device 51 (see reference). Figure 6 The diagnostic information data received from the first mobile body 40A, the second mobile body 40B and the crane terminal 30 via base stations 120 and 150, as well as the status information data generated from the diagnostic information data, are stored in the inspection information database 140.

[0054] The control device 51 of the management server 50 transmits status information data stored in the inspection information database 140 to designated information terminals 60 and 70 or crane terminals 30 via the network 130. The control device 51 of the management server 50 determines the destination of the information based on the content of the customer information database 160. The information is sent, for example, to the information terminal 70 used by the user of the crane 20 (i.e., on-site supervisors, etc.) or to the information terminal 60 used by the user (i.e., manager) who is engaged in the operation of the crane 20 remotely, and is displayed on the display screen of the information terminals 60 and 70.

[0055] In addition, Figure 1 The image shows only one crane 20 and one information terminal 60 and 70, but in reality, the management server 50 is configured to send and receive information with multiple cranes 20 or multiple information terminals 60 and 70.

[0056] [Moving Object]

[0057] Here, the first movable body 40A and the second movable body 40B will be described with reference to the accompanying drawings.

[0058] Figure 2 This is a block diagram representing the control system of the moving body 40. Furthermore, the first moving body 40A and the second moving body 40B have the same structure; therefore, when describing their identical structure, they are simply referred to as "moving body 40," while when differentiation is required, they are referred to as "first moving body 40A" and "second moving body 40B."

[0059] The mobile body 40 is a body called a drone, which has multiple rotors and flies by controlling the output of motors that drive each rotor. It can freely perform take-off and landing, forward and backward and left and right movement, and forward and reverse rotation.

[0060] The mobile body 40 moves around the crane 20 that is being inspected to take pictures of its various parts, and sends the acquired camera image data to the crane terminal 30, which serves as the processing unit, and the management server 50.

[0061] like Figure 2 As shown, the mobile body 40 includes a camera 41 as a camera mechanism, a positioning unit 421, an orientation sensor 422, a height sensor 423, a posture sensor 424, a microphone 425 as a sensor, a temperature sensor 426, a drive unit 43, a control unit 44, a data storage unit 45, a memory 46, first and second transmitting units 471 and 472, and first and second receiving units 481 and 482.

[0062] In addition, the aforementioned sensors such as the positioning unit 421, orientation sensor 422, height sensor 423, posture sensor 424, microphone 425 (which serves as a sensor), and temperature sensor 426 are just one example. The moving body 40 may not be equipped with some or all of these sensors.

[0063] The camera 41 is supported so that it is positioned facing a predetermined direction from the body of the moving body 40 and captures the scene in front of its line of sight according to the orientation of the body. The camera 41 is capable of continuously acquiring video images at a constant frame rate. Thus, it is possible to capture images of multiple parts, including those requiring maintenance. The image signals obtained through the capture are output to an image processing unit 411 connected to the camera 41. The image processing unit 411 generates captured image data in a predetermined format and stores it in a memory 46.

[0064] The aforementioned camera 41 is not limited to cameras that acquire visible light images; infrared cameras that capture infrared light can also be used. When using an infrared camera, distance image data can be obtained through methods such as phase difference.

[0065] Furthermore, it is not limited to monocular cameras; stereo cameras can also be used. In this case, distance image data can also be obtained.

[0066] The positioning unit 421 is a GNSS (Global Navigation Satellite System) receiver such as GPS (Global Positioning System) and determines the current position of the moving body 40.

[0067] The orientation sensor 422 is a three-axis gyroscope azimuth angle sensor, which detects the direction of travel of the moving body 40 and the tilt angle of the body.

[0068] The height sensor 423 is, for example, an optical sensor that shines light downwards and detects the height of the body based on the phase difference generated in the reflected light.

[0069] The posture sensor 424 consists of a three-dimensional accelerometer that detects accelerations defined along the X, Y, and Z axes of the moving body 40. The posture of the body can be detected based on the gravitational accelerations detected along these axes.

[0070] The microphone 425 is directional and detects the sound of objects located in front of it in the same direction as the line of sight of the camera 41.

[0071] Temperature sensor 426 is a non-contact so-called radiation thermometer that detects the temperature of an object located in front of the camera 41 in the same direction as the camera's line of sight.

[0072] The first transmitting unit 471 and the first receiving unit 481 communicate with the base station 120 via satellite 110.

[0073] Furthermore, the second transmitting unit 472 and the second receiving unit 482 communicate directly with the base station 150.

[0074] The drive unit 43 is a structure that outputs thrust for the movement of the moving body 40, and it has multiple rotors and multiple rotation drive sources (i.e., motors) respectively disposed on each rotor. The control unit 44 controls each motor in a manner that moves the body toward the target movement direction.

[0075] The data storage unit 45 is a non-volatile storage device for storing the control program of the mobile body 40 and various information related to control.

[0076] The memory 46 stores video image data captured by the camera 41 and detection data detected by the microphone 425 and the temperature sensor 426.

[0077] The memory 46 can be made of a non-volatile storage device. Furthermore, the memory 46 can also be made of a removable storage medium. In this case, the removable storage medium can be used to directly (without via network 130) exchange camera image data and detection data with external crane terminals 30, information terminals 60, 70, and management server 50.

[0078] The control unit 44 includes a diagnostic information collection unit 441 and a transmission unit 442. These are functional structures implemented by the central processing unit of the control unit 44 executing programs within the data storage unit 45.

[0079] The diagnostic information collection unit 441 performs motion control to move the machine body to a cameraable area containing a pre-set inspection location of the crane 20.

[0080] Furthermore, the diagnostic information collection unit 441 performs motion control to acquire camera image data and detection data by taking pictures based on the camera 41 and detecting based on the microphone 425 and the temperature sensor 426 for the part under maintenance or a specified range including the part under maintenance.

[0081] Regarding the maintenance parts of the crane 20, for example, the location coordinates of the maintenance parts defined in the coordinate system of the crane 20 are pre-stored in the data storage unit 45.

[0082] Furthermore, by positioning the moving body 40 relative to the crane 20 at a predetermined reference position with a predetermined orientation, the position coordinates of the maintenance part in the coordinate system of the current position obtained by the positioning unit 421 can be determined.

[0083] Therefore, the diagnostic information collection unit 441 can control the drive unit 43 in a way that moves the movable body 40 to an area where it can photograph the maintenance parts of the crane 20.

[0084] Furthermore, in the crane 20, there are sometimes situations where the maintenance part moves due to the rotation of the tower 24 or the boom 25. In this case, the diagnostic information collection unit 441 obtains the rotation angle information of the tower 24 or the boom 25 from the crane terminal 30 via communication with the first or second receiving units 481, 482, thereby correcting the position coordinates of the maintenance part. Then, the moving body 40 is moved to a cameraable area that includes the corrected camera position of the maintenance part.

[0085] Furthermore, a marker can be marked on a designated part of the crane 20 as an indicator. The diagnostic information collection unit 441 can detect the marker from the camera image of the crane 20 by pattern matching or the like, and move the moving body 40 to an area where the inspection part of the crane 20 can be photographed based on the detection position of the marker.

[0086] Furthermore, transmitters such as beacons are installed at designated locations on the crane 20, and corresponding receivers are installed on the moving body 40. The diagnostic information collection unit 441 determines the transmitter's transmission position and, based on this position, moves the moving body 40 to a camera-capable area containing the inspection section of the crane 20.

[0087] The transmission unit 442 performs the processing of storing the camera image data and detection data acquired by the camera 41 and the microphone 425 and temperature sensor 426 in the camera area in the memory 46.

[0088] Furthermore, the transmission unit 442 establishes a correlation between the position and posture information of the moving body 40 during shooting or detection obtained from the orientation sensor 422 and the posture sensor 424 and the video image data and detection data, and stores it in the memory 46 (hereinafter, the video image data and detection data associated with the position and posture information of the moving body 40 during shooting or detection obtained from the orientation sensor 422 and the posture sensor 424 are referred to as "diagnostic information data").

[0089] Furthermore, the transmission unit 442 transmits the same diagnostic information data as the diagnostic information data stored in the memory 46 to the crane terminal 30 and the management server 50, which are processing units, through the first and second transmission units 471 and 472.

[0090] The inspection locations of the crane 20, pre-stored in the data storage unit 45, differ between the first moving body 40A and the second moving body 40B. The first moving body 40A performs imaging and inspection in a camera-capable area (first area) of one of the inspection locations, while the second moving body 40B performs imaging and inspection in a camera-capable area (second area) of the other inspection location. These areas may partially overlap. Furthermore, the inspection locations handled by each moving body 40A and 40B may be multiple inspection locations that do not overlap with each other, or they may partially overlap.

[0091] Furthermore, the cameras 41 of each moving body 40 are not limited to filming the maintenance area, but can also film a large area including the maintenance area or a part of the crane 20 outside the maintenance area.

[0092] Furthermore, the number of mobile bodies 40 is not limited to two; one or more can be used. When using three or more, preferably, all the maintenance parts of the cranes 20 pre-stored in the data storage unit 45 are different.

[0093] Alternatively, a structure can be adopted in which the first moving body 40A takes pictures of the part to be inspected, while the second moving body 40B performs detection based on the microphone 425 and the temperature sensor 426.

[0094] In addition, regarding the mobile body 40, an example is shown where the diagnostic information collection unit 441 controls the body to move autonomously to an area where it can photograph the maintenance parts of the crane 20. However, it is also possible to adopt a structure in which the mobile body 40 can be operated by an external wireless control device, and the user (i.e., the operator) operates the wireless control device to move the mobile body 40 to an area where it can photograph the maintenance parts of the crane 20 for photographing and detection.

[0095] Figure 3 This is an explanatory diagram showing an example of the configuration of the first movable body 40A and the second movable body 40B relative to the crane 20. Figure 3 The figure shows a crane 20 in a simplified manner. Furthermore, the structures of the movable bodies 40a to 40e in the figure and the movable bodies 40f and 40g described later are the same as the structure of the movable body 40.

[0096] The first mobile body 40A and the second mobile body 40B can be configured to fly and move around the crane 20 in a state of non-physical constraint, just like the mobile body 40a.

[0097] Furthermore, the first moving body 40A and the second moving body 40B can also be configured to be connected to the crane 20 via a cable 101 reinforced with a wire rope or similar, similar to moving body 40b. The cable 101 enables power supply from the crane 20 to the moving body 40b and data communication between the moving body 40b and the crane terminal 30.

[0098] Furthermore, the cable 101 can be wound and delivered, and the reachable range of the cable 101 becomes the movable range of the movable body 40b.

[0099] Furthermore, the first movable body 40A and the second movable body 40B can also be supported in a structure that allows them to slide along the guide members 102 to 104, which are in the shape of guide rails supported on the crane 20, just like the movable bodies 40c to 40e.

[0100] Each guide member 102-104 is provided with a slider (not shown) that can slide along each guide member 102-104, and a support member (not shown) extends from the slider to support each movable body 40c-40e. The support member supports each movable body 40c-40e in a manner that allows the posture of each movable body 40c-40e to change within a certain range (i.e., has degrees of freedom).

[0101] Furthermore, it is preferable to adopt measures such as setting anti-rotation components, not setting the cross-section of each guide component 102 to 104 to be circular, and each guide component 102 to 104 being composed of multiple guide rails, so as to prevent each rotating body 40c to 40e from rotating around each guide component 102 to 104.

[0102] Furthermore, when adopting a structure in which each movable body 40c-40e is supported so that it can move along each guide member 102-104, each movable body 40c-40e can be configured to be able to walk along each guide member 102-104 but not to fly. That is, the movable bodies 40c-40e only need to be configured to be able to move around the crane, and their mode of movement is not particularly limited.

[0103] As described above, when the structure is adopted in which each moving body 40c to 40e is supported by a guide component 102 to 104, the guide component can be arranged inside the tower 24 of the crane 20. As a result, the moving body 40 can effectively photograph and inspect the maintenance areas inside the narrow tower 24, which are extremely difficult to fly through.

[0104] Furthermore, detailed examples of the movable body supported by each guide component 102 to 104 will be described later.

[0105] [crane]

[0106] according to Figure 4 The crane 20 will be described. Here, a so-called mobile tower crane is exemplified as the crane 20. In the following description of the crane 20, the direction of travel of the crane 20 (referring to the predetermined direction of travel of the lower traveling body 21 regardless of the orientation of the upper rotating body 22) is set as "forward", the direction of reversal is set as "backward", the left side in the forward-facing state is set as "left", and the right side in the forward-facing state is set as "right".

[0107] like Figure 4 As shown, the crane 20 is configured to include a self-propelled tracked lower traveling body 21, an upper slewing body 22 rotatably mounted on the lower traveling body 21, and a front attachment 23 that can be pitched and mounted on the front side of the upper slewing body 22.

[0108] The upper slewing body 22 constitutes the main body of the crane 20, and has a slewing frame 221 extending in the front-rear direction. A boom mounting part 222 is provided on the front side of the slewing frame 221, and the base end 249 of the tower 24 (described later) is mounted on the boom mounting part 222 in a tilting manner.

[0109] Furthermore, a mast mounting portion 223 is provided near the rear side of the boom mounting portion 222 in the slewing frame 221. The base end of the mast 224 (described later) is rotatably mounted on this mast mounting portion 223. Moreover, the base end of the anti-tilt device 225 (described later) is rotatably mounted on a position further rearward than the mast mounting portion 223 in the slewing frame 221.

[0110] A counterweight 226 for balancing the weight of the front attachment 23 and the load is provided on the rear side of the slewing frame 221. Furthermore, a boom tilt winch (not shown) is provided on the rear side of the slewing frame 221. On the other hand, an operator's cab 227, equipped with an operator's seat and various operating devices (not shown), is provided on the front right side of the slewing frame 221.

[0111] The front attachment 23 is mounted on the upper rotating body 22 and is used to transport materials and other goods between the ground and a higher location. The front attachment 23 is configured to include a tower 24, a boom 25, and a tower strut 26.

[0112] The tower 24 is mounted on the upper slewing body 22 in a pitchable manner. The tower 24 comprises: a lower jib 241, with its base (foot) 249 mounted in a pitchable manner on the jib mounting section 222 of the slewing frame 221; multiple (e.g., three sections) intermediate jibs 242, with their bases mounted on the ends of the lower jib 241; and an upper jib 243, mounted on the end of the most distal intermediate jib 242. A jib pitch winch 244 and a main winch 245, described later, are mounted on the lower jib 241.

[0113] like Figure 4 As shown, the support components of the intermediate booms 242 that are adjacent to each other in the length direction are connected together by connecting pins. Furthermore, the intermediate boom 242 located at the bottom and the lower boom 241, as well as the intermediate boom 242 located at the top and the upper boom 243, are also connected together by connecting pins.

[0114] The upper boom 243 is in an upright position on the tower 24. Figure 4 In the position shown, the upper boom 243 protrudes forward from the top, with its lower edge mounted at the end (upper end) of the uppermost middle boom 242. A boom 25 (described later) is mounted on the front end of the upper boom 243, allowing it to be tilted. A tower strut 26 (described later) is mounted on the upper end of the upper boom 243, allowing it to swing. Furthermore, a triangular pulley bracket 246 protrudes rearward from the upper boom 243. Tower guide pulleys 247 and 248 are rotatably mounted on this pulley bracket 246.

[0115] The jib 25 is mounted in a tilting manner to the end of the upper jib 243 of the tower 24. The jib 25 comprises: a lower jib 251, whose base is mounted in a tilting manner to the upper jib 243; an intermediate jib 252, mounted to the end of the lower jib 251; and an upper jib 253, located at the end of the intermediate jib 252. A guide pulley 254 and a point sheave 255 are rotatably mounted on the end side of the upper jib 253. A main rope 256, described later, is wound around the guide pulley 254 and the point sheave 255.

[0116] The tower strut 26 is swayably mounted on the upper end of the upper boom 243 of the tower 24. The tower strut 26 is a triangular structure formed by connecting the first strut 261, the second strut 262 and the third strut 263 through the first connecting part 264, the second connecting part 265 and the third connecting part 266.

[0117] Here, the first connecting portion 264 of the tower strut 26 is installed on the upper end side of the upper boom 243. Thus, the tower strut 26 is swayably mounted on the upper end of the tower 24 with the first connecting portion 264 as a fulcrum. Furthermore, one end of the tension rope 267 is connected to the second connecting portion 265, and the other end of the tension rope 267 is connected to the end side of the upper boom 253 of the jib 25. Moreover, the boom-side tension rope 274, described later, is connected to the third connecting portion 266.

[0118] The boom pitch winch 244 is installed on the lower boom 241 of the tower 24. The boom pitch winch 244 pitches the boom 25 via the tower strut 26. The boom pitch winch 244 is connected to the third connection 266 of the tower strut 26 by the boom pitch rope 27.

[0119] The boom pitching rope 27 is positioned between the boom pitching winch 244 and the tower strut 26. The boom pitching rope 27 comprises: a lower lifting device 271 with multiple pulleys mounted on the intermediate boom 242 of the tower 24; an upper lifting device 272 with multiple pulleys opposite to the lower lifting device 271; a winding rope 273 wound around the boom pitching winch 244 while sequentially wound around the pulleys of the lower lifting device 271 and the upper lifting device 272; and a boom side tension rope 274, one end connected to the upper lifting device 272 and the other end connected to the third connection 266 of the tower strut 26.

[0120] Therefore, by winding or unwinding the winding rope 273 with the boom pitch winch 244, the upper lifting device 272 moves closer to or further away from the lower lifting device 271, and the tower strut 26 swings with the first connection 264 as the fulcrum. The swing of the tower strut 26 is transmitted to the boom 25 via the tension rope 267, thereby causing the boom 25 to pitch at the end of the tower 24.

[0121] The main winch 245 is located near the upper side of the boom pitch winch 244 and is installed on the lower boom 241 of the tower 24. The main winch 245 has the main rope 256 wound around it at one end. The other end of the main rope 256 is connected to the hook 28 via the guide pulley 248 of the pulley bracket 246, the guide pulley 254 of the boom 25, and the paving pulley 255. Therefore, the hook 28 can be raised or lowered by winding or unwinding the main rope 256 with the main winch 245.

[0122] An anti-tilting device 225 is disposed between the slewing frame 221 and the lower boom 241 of the tower 24. The anti-tilting device 225 supports the tower 24 from behind when it is in an upright position.

[0123] The base of the mast 224 is rotatably mounted to the mast mounting portion 223 of the slewing frame 221. The end of the mast 224 is a free end that can rotate in the vertical direction and even the front-back direction.

[0124] A boom spreader 228 is provided at the end of the mast 224. The boom spreader 228 is connected to the upper boom 243 of the tower 24 via a rope 229 of a certain length. Furthermore, the boom pitch rope 291 of the spreader (not shown) that is wound sequentially around the boom spreader 228 and the spreader (not shown) on the side of the slewing frame 221 is wound around the tower pitch winch (not shown) provided on the slewing frame 221.

[0125] Therefore, if the tower pitch winch winds the jib pitch rope 291, the tension rope 229 can be pulled to raise the tower 24. On the other hand, if the tower pitch winch releases the jib pitch rope 291, the tower 24 can be tilted (fallen) toward the ground via the tension rope 229.

[0126] Figure 5 This is a block diagram showing the structure of the crane terminal 30. The crane terminal 30 is a control terminal mounted on the crane 20, which performs control of various actions of the crane 20, such as traveling, rotating, and lifting, as well as abnormal detection and handling.

[0127] The crane terminal 30 includes a controller 31, which includes an arithmetic processing unit with a CPU, storage devices (i.e., ROM and RAM) and other peripheral circuits.

[0128] like Figure 5 As shown, the controller 31 is connected to a force sensor 321, a boom angle sensor 322, an operation quantity sensor 323, a boom angle sensor 324, an input unit 331, a display device 332, an alarm 341, a stop device 342, first and second transmitting units 351 and 352, first and second receiving units 361 and 362, an operating lever 37, and a control valve 38.

[0129] Force sensor 321 is installed on boom lifting device 228. It detects the tension of boom pitching rope 291 that acts to pitch the tower 24 and outputs a control signal corresponding to the detected tension to controller 31.

[0130] The input unit 331 is, for example, a touch panel, which outputs control signals corresponding to the operator's operation to the controller 31. The operator can operate the input unit 331 to set the number of turns of the main winding rope 256, the tower length, and the mass of the lifting hook 28, etc.

[0131] The boom angle sensor 322 is installed on the base end side of the tower 24. It detects the pitch angle of the tower 24 (hereinafter also referred to as the boom angle) and outputs a control signal corresponding to the detected boom angle to the controller 31. For example, the boom angle sensor 322 detects the angle relative to the horizontal plane (i.e., the angle with respect to the ground) as the boom angle.

[0132] A boom angle sensor 324 is mounted on the base end of the boom 25. It detects the pitch angle of the boom 25 (hereinafter also referred to as the boom angle) and outputs a control signal corresponding to the detected boom angle to the controller 31. For example, the boom angle sensor 324 detects the angle relative to the horizontal plane (i.e., the angle relative to the ground) as the boom angle.

[0133] The operation amount sensor 323 detects, for example, the operation amount of a hydraulic pilot-operated lever and outputs a control signal corresponding to the detected operation amount to the controller 31.

[0134] The display device 332 includes, for example, a touch panel display that also serves as an input unit 331, and displays information about the suspended load and the working posture on the display screen according to the control signal output from the controller 31.

[0135] The alarm 341 issues an alarm based on the control signal output from the controller 31.

[0136] The stopping device 342 stops the drive of the hydraulic motors (not shown) connected to the main winch 245 and the boom pitch winch 244 respectively, based on the control signal output from the controller 31. The stopping device 342 is, for example, an electromagnetic switching valve capable of cutting off the supply of pressurized oil from the hydraulic pump to the hydraulic motor.

[0137] The first transmitting unit 351 and the first receiving unit 361 communicate with the base station 120 via satellite 110.

[0138] Furthermore, the second transmitting unit 352 and the second receiving unit 362 communicate directly with the base station 150.

[0139] The controller 31 functionally includes a load calculation unit 311, a winch control unit 312, a display control unit 313, and a transmission control unit 314.

[0140] The load calculation unit 311 calculates the suspension load applied to the hook 28 of the suspended object based on the output of the force sensor 321 and the boom angle sensor 322.

[0141] The winch control unit 312 determines whether the suspended load exceeds the rated total load. If it does, it outputs a stop signal to the stop device 342 and an alarm signal to the alarm device 341. If a stop signal is input to the stop device 342, the operation of the boom pitch winch 244 and the main winch 245 is stopped. If an alarm signal is input to the alarm device 341, an alarm is triggered.

[0142] The display control unit 313 controls the image displayed on the display screen of the display device 332. The display control unit 313 displays the suspension load calculated by the load calculation unit 311 on the display screen of the display device 332.

[0143] Furthermore, the display control unit 313 displays the information managed by the management server 50 on the display screen of the display device 332.

[0144] The transmission control unit 314 transmits information stored in the storage device of the controller 31 via the first transmission unit 351 or the second transmission unit 352 at a predetermined time. The information transmitted from the first transmission unit 351 or the second transmission unit 352 is received by the base stations 120 and 150 and transmitted to the management server 50.

[0145] Furthermore, the transmission control unit 314 transmits the rotation angle information, which is composed of the boom angle and the boom angle detected by the boom angle sensor 322 and the boom angle sensor 324, to each moving body 40 via the first transmission unit 351 or the second transmission unit 352.

[0146] Furthermore, the transmission control unit 314 transmits diagnostic information data received from each mobile body 40 to the management server 50 via the first transmission unit 351 or the second transmission unit 352.

[0147] The control valve 38 consists of multiple valves that can be switched according to control signals from the controller 31.

[0148] For example, control valve 38 includes: a valve that switches the supply, cut-off, and rotation direction of hydraulic pressure from the hydraulic pump of the crane 20 to the hydraulic motor that drives the drive wheel of the lower traveling body 21; a valve that switches the supply, cut-off, and rotation direction of hydraulic pressure from the aforementioned hydraulic pump to the hydraulic motor that drives the upper rotating body 22 to rotate; a valve that switches the supply, cut-off, and rotation direction of hydraulic pressure from the aforementioned hydraulic pump to the hydraulic motor that drives the tower pitch winch; a valve that switches the supply, cut-off, and rotation direction of hydraulic pressure from the aforementioned hydraulic pump to the hydraulic motor that drives the boom pitch winch 244 to rotate; and a valve that switches the supply, cut-off, and rotation direction of hydraulic pressure from the aforementioned hydraulic pump to the hydraulic motor that drives the main winch 245 to rotate, etc.

[0149] The operating lever 37 consists of multiple levers that switch control signals input to various valves of the control valve 38 via the controller 31.

[0150] For example, the travel lever, which is one of the operating levers 37, inputs a switching signal to the valve that controls the supply, stop, and rotation direction of hydraulic power to the hydraulic motor that drives the drive wheel of the lower travel body 21 to rotate.

[0151] Furthermore, the rotary lever, one of the operating levers 37, switches the hydraulic supply, stop, and rotation direction of the hydraulic motor that drives the upper rotary body 22 to rotate via the hydraulic pump, as described above, by inputting a valve switching signal.

[0152] Furthermore, the boom pitch lever, one of the operating levers 37, receives a switching signal from the hydraulic pump to the hydraulic motor that drives the tower pitch winch to switch the supply, stop, and rotation direction of hydraulic pressure.

[0153] Furthermore, the boom pitch lever, one of the operating levers 37, switches the hydraulic supply, stop, and rotation direction of the hydraulic motor that drives the boom pitch winch 244 to rotate via a valve input switching signal.

[0154] Furthermore, the winch lever, one of the operating levers 37, receives a valve input switching signal to switch the hydraulic supply, stop, and rotation direction of the hydraulic motor that drives the main winch 245 to rotate from the hydraulic pump.

[0155] The controller 31 inputs control signals corresponding to the supply, stop and rotation direction switching of hydraulic pressure to each valve of the corresponding control valve 38 according to the operation of the various levers constituting the operating lever 37, thereby executing the control of each hydraulic motor.

[0156] Thus, the operator can operate the control lever 37 to perform the traveling motion of the crane 20, the slewing motion of the upper rotating body 22, the pitching motion of the tower 24, the pitching motion of the boom 25, and the lifting motion of the hook 28.

[0157] In addition, in the example of the crane terminal 30 described above, the structure for handling abnormalities, such as the force sensor 321, the boom angle sensor 322, the operation quantity sensor 323, the boom angle sensor 324, the limit switch (not shown), the alarm 341, and the stop device 342, and the structure for normal operation, such as the operating lever 37 and the control valve 38, are centrally controlled by the control system. However, it can also be configured such that the structure for handling abnormalities and the structure for normal operation each have independent controllers for separate control, thus becoming an independent system.

[0158] [Manage Server]

[0159] Figure 6 This is a block diagram showing the structure of the management server 50. The management server 50 includes a control unit 51, a storage unit 52, and a communication unit 53.

[0160] The control device 51 is configured to include an arithmetic processing unit with a CPU and peripheral circuitry. The control device 51 controls the various parts of the management server 50 by reading and executing a control program pre-stored in the storage unit 52.

[0161] Storage unit 52 is, for example, a non-volatile storage device.

[0162] The communications unit 53 conducts data communication (sending and receiving) via network 130 in a prescribed order.

[0163] A display device 54 is connected to the control device 51. The control device 51 displays the information stored in the storage unit 52, the crane inspection information database 140, or the customer information database 160 on the display screen of the display device 54.

[0164] The control device 51 is connected to the crane inspection information database 140 and the customer information database 160. Figure 7 This is a diagram representing an example of information stored in the crane inspection information database 140.

[0165] The control device 51 establishes associations between the date and time information 141 indicating the date and time of receipt received from each mobile body 40 via base stations 120 and 150 (including via crane terminal 30), the construction machine ID 142 inherent to the crane 20, and the diagnostic results 143 described later, and stores them in the crane's inspection information database 140.

[0166] Figure 8This diagram illustrates an example of information stored in the customer information database 160. The customer information database 160 stores construction machine IDs 161 of cranes 20 that are associated with each other, one or more customer information 162 related to customers who own cranes 20, and one or more customer mailing addresses 163. Furthermore, the mailing address 163 corresponding to a customer with a construction machine ID 161 can be freely changed. Multiple mailing addresses 163 can also be set for a customer with a single construction machine ID 161.

[0167] Therefore, when the information in the crane inspection information database 140 is updated for a specific crane 20, the control device 51 of the management server 50 determines the customer and their mail receiving address, and then sends the updated information about the crane 20 or a notification of the update.

[0168] Furthermore, if access is available from the customer's side, the control device 51 may permit the transmission or viewing of various information related to the customer's crane 20 stored in the crane inspection information database 140.

[0169] At this point, a password can be set for each customer in the customer information database 160, and the customer will be asked to enter the password when accessing the site. Preferably, the password is also registered in the customer information database 160.

[0170] The control device 51 functionally includes a diagnostic processing unit 511, an image processing unit 512, and a display processing unit 513.

[0171] The diagnostic processing unit 511, the image processing unit 512, and the display processing unit 513 will be described in turn.

[0172] [Diagnostic Treatment Department]

[0173] The diagnostic processing unit 511 uses diagnostic information data, including camera image data and detection data, obtained from each moving body 40 to determine whether any abnormalities have occurred in the inspection items described below for the maintenance parts of the crane 20.

[0174] The following items are to be checked.

[0175] (1) Cracks, deformation, and damage to the tower and boom.

[0176] (2) Wear and damage to foot pins, connecting pins, and bushings.

[0177] (3) Wear, damage, tangling, and terminal condition of the wire rope

[0178] (4) Damage and corrosion of the rope

[0179] (5) Cracks, deformations, and damage to various lifting tools, gantry cranes, and tower struts.

[0180] (6) Cracks, deformation, and wear on the lifting hook.

[0181] (7) Working condition, deformation, and damage of the anti-derailment components of the wire rope of the lifting hook.

[0182] (8) Loose nuts, damaged threads, or corrosion on the lifting hook.

[0183] (9) Wear, deformation, and damage of each pulley

[0184] (10) Working status of the anti-overwinding devices for lifting hooks, towers, and booms.

[0185] (11) Working status of force sensor and boom angle sensor

[0186] (12) Deformation or damage to the anti-tilt device

[0187] (1) Cracks, deformation, and damage to the tower and boom.

[0188] The diagnostic processing unit 511 determines the presence or absence of cracks, deformations, and damage based on the camera image data of the tower 24 and boom 25 included in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on the determination results.

[0189] Regarding "cracks" and "damage," the diagnostic processing unit 511 uses a pattern recognition algorithm, which is obtained through machine learning and defines parameters for damage or cracks in the tower and boom, to perform "crack" or "damage" detection. If "cracks" or "damage" are detected, it is diagnosed as abnormal; if not detected, it is diagnosed as normal.

[0190] Furthermore, regarding "deformation," the diagnostic processing unit 511 compares the image data of the normal tower 24 or boom 25 with the camera image data and makes a determination based on the consistency using known methods such as pattern matching. Alternatively, similar to "cracks" and "damage," a pattern recognition device with defined deformation parameters can be used to perform the detection of the "deformation" portion.

[0191] (2) Wear and damage to foot pins, connecting pins, and bushings.

[0192] The diagnostic processing unit 511 determines the presence or absence of wear and damage to the foot pins, connecting pins, and bushings used in the tower 24 and boom 25 based on the camera image data of the tower 24 and boom 25 contained in the diagnostic information data from the mobile body 40, and diagnoses any abnormalities based on the determination results.

[0193] Regarding "wear," the diagnostic processing unit 511 calculates the size of the worn area from camera image data of the foot pins, connecting pins, or bushings of the tower 24 or boom 25, thereby obtaining the amount of wear. Next, it determines whether the amount of wear is within a specified range, thus identifying any abnormalities.

[0194] Furthermore, the method for detecting "damage" is the same as the previously documented method.

[0195] (3) Wear, damage, tangling, and terminal condition of the wire rope

[0196] The diagnostic processing unit 511 uses the camera image data of the tower 24 and boom 25 included in the diagnostic information data from the mobile body 40 to determine the wear, damage, presence or absence of tangled ropes in the main winding rope 256, boom pitch rope 27, and luffing boom pitch rope 291, as well as the condition of the end points, and diagnoses any abnormalities based on these determination results.

[0197] Regarding "damage" and "tangle," the diagnostic processing unit 511 uses a pattern recognition reader, which is obtained through machine learning and defines parameters for the damage and tangle states of each rope, to perform "damage" or "tangle" detection. Damage and tangle states include the occurrence of twisting and the occurrence of breakage.

[0198] Alternatively, a pattern recognition reader that defines parameters for the normal winding state of each rope can be used to detect the normal winding state. In this case, if a "tangled rope" is detected, it is diagnosed as abnormal; if a "normal winding state" is detected, it is diagnosed as normal.

[0199] Furthermore, regarding the "terminal status," the diagnostic processing unit 511 uses a pattern recognition reader, which is obtained through machine learning and defines parameters for the abnormal status of each rope's terminal, to detect the "abnormal status" of the terminal. Alternatively, a pattern recognition reader, which defines parameters for the normal status of each rope's terminal, can be used to detect the "normal status" of the terminal. In this case, if an "abnormal status" is detected, it is diagnosed as abnormal; if a "normal status" is detected, it is diagnosed as normal.

[0200] Furthermore, the methods for detecting "wear" and "damage" are the same as those already described.

[0201] (4) Damage and corrosion of the rope

[0202] The diagnostic processing unit 511 determines the presence or absence of damage and corrosion of the tension rope 267 and boom-side tension rope 274 based on the camera image data of the tower 24 and boom 25 contained in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on these determination results.

[0203] Regarding "corrosion," the diagnostic processing unit 511 uses a pattern recognition device that defines the corrosion state of the rope, obtained through machine learning, to perform "corrosion" detection. If "corrosion" is detected, it is diagnosed as abnormal; if not detected, it is diagnosed as normal.

[0204] Furthermore, the method for detecting "damage" is the same as the previously documented method.

[0205] (5) Cracks, deformations, and damage to various lifting tools and tower struts.

[0206] The diagnostic processing unit 511 determines the presence or absence of cracks, deformations, and damages in the boom sling 228, lower sling 271, upper sling 272, and tower strut 26 based on the camera image data of the tower 24 and boom 25 included in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on the determination results.

[0207] The detection methods for "cracks", "deformation" and "damage" are the same as those already recorded.

[0208] (6) Cracks, deformation, and wear on the lifting hook.

[0209] The diagnostic processing unit 511 determines the presence or absence of cracks, deformations, and wear on the hook 28 of the suspended object based on the camera image data of the boom 25 included in the diagnostic information data from the moving body 40, and determines whether there is any abnormality based on the determination result.

[0210] The testing methods for "cracking", "deformation" and "wear" are the same as those already recorded.

[0211] (7) Working condition, deformation, and damage of the anti-derailment components of the wire rope of the lifting hook.

[0212] The diagnostic processing unit 511 determines the working status, deformation, and presence of damage of the wire rope anti-derailment device installed on the hook 28 of the suspended object based on the camera image data of the boom 25 included in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on the determination results.

[0213] Regarding the "working status", the diagnostic processing unit 511 compares the video images of the working status before working and the video images of the working status after working with the images of the normal working status before working or the normal working status after working, and determines whether it is correct based on the consistency of known methods such as pattern matching.

[0214] Furthermore, the detection methods for "deformation" and "damage" are the same as those already recorded.

[0215] (8) Loose nuts, damaged threads, or corrosion on the lifting hook.

[0216] The diagnostic processing unit 511 determines the looseness of the nut, damage to the thread, and presence of corrosion of the boom 25 in the diagnostic information data included in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on the determination results.

[0217] Regarding "loose nuts," the diagnostic processing unit 511 compares the image of the nut with either an image of the nut in a loose state or an image of the nut in a tight state, and determines whether it is loose based on the degree of consistency using known methods such as pattern matching. If the image of the nut matches the image of the nut in a loose state, it is diagnosed as abnormal; if it matches the image of the nut in a tight state, it is diagnosed as normal.

[0218] Alternatively, the protrusion length of the nut from the installation position can be determined from the camera image of the nut. If the protrusion length exceeds the specified value, it is diagnosed as abnormal.

[0219] Furthermore, the detection methods for "damage" and "corrosion" are the same as those already described.

[0220] (9) Wear, deformation, and damage of each pulley

[0221] The diagnostic processing unit 511 determines the wear, overall deformation, and presence of damage to the grooves of the tower guide pulleys 247, 248, 254, and point pulleys 255 based on the camera image data of the tower 24 and boom 25 included in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on the determination results.

[0222] The detection methods for "wear," "deformation," and "damage" are the same as those already recorded.

[0223] (10) Working status of the anti-overwinding devices for lifting hooks, towers, and booms.

[0224] The diagnostic processing unit 511 diagnoses whether the over-winding prevention device installed on the wire ropes of the moving body 40 is functioning properly based on the camera image data of the boom 25 included in the diagnostic information data from the moving body 40.

[0225] To prevent over-winding, the over-winding prevention device stops the lifting hook 28, tower 24, and boom 25 at a stop position just before over-winding occurs during normal operation. The diagnostic processing unit 511 determines whether the device is functioning normally based on whether the stopping positions in the camera images of their stopped states are within the normal range. Specifically, the diagnostic processing unit 511 calculates the height of the lifting hook 28, the tilt angle of the tower 24, and the tilt angle of the boom 25 from the camera images and diagnoses any abnormalities based on these values.

[0226] (11) Working status of force sensor and boom angle sensor

[0227] The diagnostic processing unit 511 diagnoses whether a condition is normal or abnormal based on the detection data of the force sensor 321 and the boom angle sensor 322 included in the diagnostic information data from the crane terminal 30 and the values ​​of these detection data.

[0228] (12) Operation, deformation, and damage of the anti-tilt device

[0229] The diagnostic processing unit 511 determines the presence or absence of deformation and damage to the anti-tilt device 225 based on the camera image data of the tower 24 included in the diagnostic information data from the moving body 40, and diagnoses any abnormalities based on the determination results.

[0230] The detection methods for "deformation" and "damage" are the same as those already recorded.

[0231] The diagnostic processing unit 511 performs diagnostics on the inspection items (1) to (12) above, and stores the diagnostic results together with the date and time information of the photograph as part of the status information data of the corresponding crane 20 in the inspection information database 140.

[0232] Image Processing Department

[0233] The image processing unit 512 processes the camera image data of the crane 20, which is included in the diagnostic information data obtained from each moving body 40, into processed image data suitable for the user to make anomaly judgments.

[0234] The image processing unit 512 generates processed image data of the three-dimensional model of the crane 20 as processed image data suitable for anomaly detection.

[0235] The image processing unit 512 generates processed image data of a three-dimensional model based on the camera image data contained in the diagnostic information data obtained from each moving body 40.

[0236] Each frame of the video image data includes data indicating the shooting position and orientation of the moving body 40. Therefore, common feature points are extracted from multiple video image data obtained by shooting the same part of the crane 20 and their positions in each image are determined, thereby enabling the calculation of the three-dimensional coordinates of the feature points.

[0237] Therefore, by extracting multiple feature points from the camera images of the maintenance parts of the crane 20, calculating the three-dimensional coordinates, and connecting the feature points, it is possible to generate machining image data of a three-dimensional model of the maintenance parts of the crane 20. The machining image data of the three-dimensional model can display the external shape of each part of the crane 20 from various directions, and therefore can also be used to diagnose whether there are any abnormalities in the crane 20.

[0238] Furthermore, when the camera 41 of each moving body 40 is equipped with an infrared camera or a stereo camera, distance data can be obtained according to the pixels of the captured image, thus enabling the generation of processed image data of a higher precision three-dimensional model.

[0239] Furthermore, even if each moving body 40 is not equipped with a positioning unit 421 that can obtain position coordinates using GPS, as long as the moving speed of the moving body 40 during the capture of consecutive frames can be detected, multiple feature points can be extracted from the camera image to generate the processed image data of the three-dimensional model in the manner described above.

[0240] The image processing unit 512 stores the processed image data of the manufactured three-dimensional model of the crane 20, along with the shooting date and time information, as part of the corresponding status information data of the crane 20 in the inspection information database 140.

[0241] Display Processing Department

[0242] The display processing unit 513 performs display processing of various information registered in the crane inspection information database 140 as status information data indicating the status of the crane 20.

[0243] The status information to be displayed includes, for example, diagnostic results of the crane 20 based on the diagnostic processing unit 511, processed images of the crane 20's three-dimensional model based on the image processing unit 512, photographic images based on camera image data acquired from the moving body 40, character information related to the photographic images (the shooting location of the crane 20, the shooting date and time), and information on the detection data acquired from the moving body 40. If the number of captured images is large, for example, only a portion of the representative images used in the diagnostic process can be used.

[0244] Furthermore, the display processing unit 513 is not limited to the display on the display device 54 connected to the management server 50, but can also be displayed from the communication unit 53 via the network 130 on external information terminals 60, 70 or crane terminal 30.

[0245] Furthermore, when displaying information to external terminals 30, 60, and 70, the following restrictions can be set: after confirming that the display object is a specific customer by referring to the customer information database 160, only status information related to the crane 20 of that customer is displayed. Also, regarding display processing, status information data can be sent to the customer's terminals 30, 60, and 70, or it can be set to not send status information data and only allow viewing of status information.

[0246] [Technical Effects of the Embodiments of the Invention]

[0247] The crane maintenance system 100 described above includes a processing unit (i.e., server 50) that performs prescribed processing on camera image data captured by each moving body 40 moving around the crane 20. Therefore, even when maintaining objects that are at heights, such as the boom and jib of the crane 20, maintenance work on the crane 20 can be easily performed.

[0248] Furthermore, the diagnostic processing unit 511 of the management server 50 determines whether there is an abnormality in the maintenance part of the crane 20 based on the camera image data, thus making it easy and quick to obtain an objective judgment and enabling more effective and convenient maintenance work.

[0249] Furthermore, the image processing unit 512 of the management server 50 processes the camera image data into processed image data suitable for users to make anomaly judgments. Therefore, compared with simply observing the camera image, anomaly judgments can be made easily and accurately.

[0250] In particular, the three-dimensional model data of the crane 20 is used as processing image data. Therefore, the processing image data of the three-dimensional model can display the external shape of each part of the crane 20 from all directions, and anomaly judgment can be made more meticulously even when the crane 20 is far away from the site, as if the site is being visited.

[0251] Furthermore, the display processing unit 513 of the management server 50 performs display processing, which collects status information data representing the status of the crane 20 into the inspection information database 140 and displays the status information contained in the status information data and the processing image based on the processing image data to the user.

[0252] Therefore, even if the user does not go to the site of the crane 20, they can still grasp the status of the crane 20 and effectively carry out maintenance and management.

[0253] Furthermore, the mobile body 40 sends camera image data to the crane terminal 30 of the crane 20, and the management server 50 collects status information data and camera image data representing the status of the crane 20 from the crane terminal 30.

[0254] Therefore, the management server 50 can collect camera image data using the existing network connected to the crane terminal 30, and does not require the network connection environment of the mobile body 40, thus making it easy to build a crane maintenance system.

[0255] Furthermore, the moving body 40 obtains pitch information from the crane terminal 30, which indicates the pitch state of the tower 24 of the crane 20, and determines the shooting position based on the pitch information. Therefore, even if the crane 20 changes its posture, it can obtain accurate camera image data.

[0256] Furthermore, the moving body 40 has different sensors than the camera 41 (i.e., microphone 425 and temperature sensor 426), and uses these sensors to detect the crane 20, thus enabling the collection of a variety of data and more accurate crane diagnosis.

[0257] Furthermore, by using the first moving body 40A and the second moving body 40B to take pictures of different first and second areas respectively, the shooting work can be effectively carried out when there are multiple maintenance parts of the crane 20.

[0258] Furthermore, when a structure is adopted in which a first moving body 40A with a camera 41 and a second moving body 40B with a microphone 425 and a temperature sensor 426 are used for shooting and detection respectively, the first moving body 40A can move only along the path of a position suitable for shooting, and the second moving body 40B can move only along the path of a position suitable for detection, thus enabling the effective collection of diagnostic information data.

[0259] Furthermore, when a structure is adopted in which the moving body 40 (including the moving bodies 40f and 40g described later) moves along the guide members 102 to 104 provided on the crane 20, vibrations of the moving body 40 can be suppressed, thereby enabling the acquisition of good camera image data.

[0260] Furthermore, when a structure is adopted in which the guide component is placed inside the tower 24 of the crane 20 and the moving body 40 moves inside the tower 24, it is also possible to photograph and inspect the inside of the tower 24, which the flying moving body 40 cannot enter due to fear of contact with its surroundings.

[0261] [other]

[0262] The details shown in the embodiments of the above invention can be appropriately changed without departing from the spirit of the invention.

[0263] For example, in the above-mentioned crane maintenance system 100, a tower crane is shown as an example of crane 20, but it is not limited to this. In addition to mobile cranes such as crawler cranes, wheeled cranes, and truck cranes, it can also be applied to all cranes such as port cranes, bridge cranes, cantilever cranes, gantry cranes, unloaders, and stationary cranes.

[0264] Furthermore, this invention is not limited to cranes equipped with lifting hooks; cranes with attachments such as magnets or drilling buckets are also applicable.

[0265] Furthermore, the inspection items in the diagnostic processing unit 511 described above are just one example, and may include a portion of these items or other inspection items. In particular, when the above applies to various types of cranes, it is preferable to perform diagnostic processing on more appropriate inspection items according to the type.

[0266] Furthermore, while pattern recognition devices have been used in various diagnostic procedures to detect abnormalities in camera image data, this approach is not the only one. For example, other known methods, such as pattern matching, can also be used to detect abnormalities.

[0267] [Example of a moving body supported by a guide component (1)]

[0268] Example (1) of a movable body supported by guide components 102 to 104 will be described in detail with reference to the accompanying drawings.

[0269] Figure 9 This is the front view of the aforementioned moving body 40f. Figure 10 It is the left view. Figure 11 This is a left view of the movable body 40f supported by the guide component 103. Figure 12 It is a top view.

[0270] The mobile body 40f is a so-called drone that moves by obtaining thrust from multiple rotors, such as... Figure 9 and Figure 10 As shown, cameras 41f, which capture images from the front, back, left, and right, are mounted on the lower part of the body via a universal bracket mechanism 412f.

[0271] The universal support mechanism 412f supports each camera 41f so that its orientation can be changed around the three axes of vertical direction: up and down, left and right, and front and back.

[0272] Furthermore, the lower part of the body is equipped with a pair of support legs 413f. When the moving body 40f touches the ground, these support legs 413f rotate downward to protect each camera 41f, and during movement, they move upward to avoid obstructing filming.

[0273] A support member 494f extends to the left from a slider 49f that can slide along each guide member 102-104, connected to the right side surface of the body of the movable body 40f. A ball joint 495f is provided in the middle part of the support member 494f, which allows the movable body 40f to swing slightly up and down and back and forth, and can also change its posture around the left and right axis.

[0274] exist Figure 11 and Figure 12The diagram illustrates guide members 103 supported on tower 24. Tower 24 has four main iron pipes arranged in a box shape along the length of the jib. Inside the four main iron pipes, two pairs of guide members 103 are supported parallel to the main iron pipes by suspension members 105 suspended between two main iron pipes at intervals. Each pair of guide members 103 is composed of a circular tube of a certain length and is connected to the required length by a rubber joint 107.

[0275] Other guide components 102 and 104 also have the same structure and are supported by the same support structure.

[0276] Figure 13 This is a top view of the slider 49f, which allows the moving body 40f to slide along the guide members 102-104. Figure 14 This is the left view of slider 49f. Figure 15 This is the main view.

[0277] The slider 49f comprises two units, upper and lower, consisting of three wheels 491f on the left, right, and front sides of the guide members 102-104 arranged in a front-to-back configuration, three wheels 491f on the left, right, and rear sides of the guide members 102-104 arranged in a front-to-back configuration, a pair of support frames 492f supporting these wheels 491f to surround the pair of guide members 102-104 and to be rotatable, and a connecting body 493f supporting the pair of support frames 492f to be rotatable about an axis in the front-to-back direction.

[0278] Furthermore, the slider 49f includes a support body 496f that supports the upper unit to rotate about an axis in the vertical direction and a support body 497f that supports the lower unit to rotate about an axis in the vertical direction. The upper and lower support bodies 496f and 497f are connected by a connecting shaft 498f that enables the upper and lower support bodies 496f and 497f to rotate about an axis in the front-back direction and an axis in the left-right direction. The connecting shaft 498f is connected to the aforementioned support member 494f.

[0279] The moving body 40f is supported on the guide member 103 in the above configuration, so that it can take pictures in four directions from the inside of the tower 24.

[0280] Furthermore, since the six wheels 491f surround the pair of guide members 102-104 from four directions, rotation around the guide members 102-104 is prevented, and the moving body 40f can move stably while taking pictures.

[0281] Furthermore, through the aforementioned structure of slider 49f, as... Figure 14 and Figure 15As shown, even when the guide members 102 to 104 are bent in a certain direction, the upper and lower units can move smoothly along the bent guide members 102 to 104 by allowing different orientations.

[0282] Furthermore, the moving body 40f can also move by applying travel power from the drive source to the wheels that are in contact with the guide members 102-104, but here it is designed to obtain thrust through the rotation of the rotor. Therefore, wheel slippage is avoided, and stable movement is possible. Moreover, in the case of wheel drive, the mechanism for transmitting power to the wheels becomes complex, but this problem does not exist in the rotor case, simplifying the structure.

[0283] In addition, Figure 11 and Figure 12 The example shown illustrates a structure in which the movable body 40f can move along the guide member 103 provided within the tower 24. However, by also supporting the guide member 104 with the same structure within the boom 25, the movable body 40f can also capture images within the boom 25. Similarly, by providing the guide member 102 with the same support structure on the side surfaces of the lower traveling body 21 and the upper rotating body 22, images of the lower traveling body 21 and the upper rotating body 22 can be captured.

[0284] [Example of a moving body supported by a guide component (2)]

[0285] Example (2) of a movable body supported by guided components 102 to 104 will be described in detail with reference to the accompanying drawings.

[0286] Figure 16 This is a top view of the aforementioned moving body, 40g. Figure 17 This is a top view of the body with 40g of moving parts removed, resulting in a weight of 416g from the upper surface. Figure 18 The front view shows the part with 496g of the side wall of the fuselage cut off. Figure 19 This is a top view of the movable body 40f supported by the guide component 103. Figure 20 This is the main view.

[0287] The 40g mobile body is also a so-called drone that moves by obtaining thrust through multiple rotors, such as... Figures 16-18 As shown, it moves along a guide component 102-104.

[0288] like Figure 19 and Figure 20 As shown, the guide component ( Figure 19 and Figure 20 The example shows a guide member 103 supported on a tower 24, which is located at the center of the tower 24 on the inside of four main iron pipes arranged in a box shape along the length of the boom of the tower 24.

[0289] For example, the guide member 103 is supported at a certain interval from the main iron pipe by a strut 106 extending from a suspension member 105 between two of the four main iron pipes of the tower 24, which are suspended at constant intervals.

[0290] The guide component 103 is made of a circular tube of a certain length and is connected to the required length by a rubber joint 107. This enables stable movement of the moving body 40.

[0291] Other guide components 102 and 104 also have the same structure and are supported by the same support structure.

[0292] In the moving body 40g, three cameras 41g, which shoot the front, back, and left sides respectively, are set on the outer wall of the body, while the camera 41g that shoots the right side is set on the upper surface 416g of the body. This is to avoid the support column 106 of the support guide component 103.

[0293] Furthermore, a power supply unit 414g and a control unit 415g are also provided on the upper surface 416g of the body.

[0294] The guide components 102-104 penetrate the center of the 40g moving body from top to bottom.

[0295] In the guide members 102 to 104, guide grooves are formed along the length direction at the front, rear, and left positions on the outer periphery. Furthermore, inside the body of the moving body 40g, three wheels 491g are rotatably supported and inserted into and abut against the guide grooves 102a to 104a of the guide members 102 to 104 from the front, rear, and left directions, and sliding along the guide members 102 to 104 is achieved by these wheels 491g.

[0296] The moving body 40g is supported on the guide member 103 in the above configuration, so that it can take pictures in four directions from the inside of the tower 24.

[0297] Furthermore, since the three wheels 491g surround each guide component 102-104 from three directions, rotation around the guide components 102-104 is prevented, and the moving body 40g can move stably while shooting.

[0298] Furthermore, the moving body 40g is structured to surround each guide component 102-104 with three wheels 491g. Therefore, even if the guide components 102-104 bend in a certain direction, it is less affected and can move smoothly along the bent guide components 102-104.

[0299] Furthermore, the moving body 40g can also be moved by applying driving power from the drive source to the wheels that are in contact with the guide components 102-104, but here it is designed to obtain thrust through the rotation of the rotor. As a result, stable movement without slippage and structural simplification can be achieved.

[0300] In addition, Figure 19 and Figure 20 The example shown illustrates a structure in which the movable body 40g can move along the guide member 103 provided within the tower 24. However, by also supporting the guide member 104 with the same structure within the boom 25, the movable body 40f can also capture images within the boom 25. Similarly, by providing the guide member 102 with the same support structure on the side surfaces of the lower traveling body 21 and the upper rotating body 22, images of the lower traveling body 21 and the upper rotating body 22 can be captured.

[0301] Additionally, the moving body 40 can also capture images of the area around the lower traveling body 21 and the upper rotating body 22 for monitoring the crane's perimeter. Furthermore, it can capture images of the area around the crane's hook for monitoring the load. In other words, the images captured by the moving body 40 can be used to assist in capturing images of crane operations other than maintenance.

[0302] Furthermore, an example is shown here where the guide member 103 is supported by a strut 106 extending from the suspension member 105 suspended on the two main iron pipes of the tower 24, but the support structure is not limited to this.

[0303] For example, such as Figure 21 As shown, a structure can also be adopted in which the ends of the two main iron pipes of the tower 24 extend to the two support pipes 105a and 105b near the center and are connected to the base end of the support column 106, and the guide member 103 is supported by the end of the support column 106. Furthermore, the same support structure can also be applied to the guide members 102 and 104.

[0304] In addition, regarding the above Figures 16-20 The movable body 40g shown can be supported by a structure in which the three wheels 491g are pressed against the guide members 102-104 by springs and dampers.

[0305] Furthermore, the following structure can also be adopted: a guide rail-shaped electrode extending along the guide members 102 to 104 is provided near the guide grooves 102a to 104a of any one of the guide members 102 to 104, and a power brush that slides on the guide rail-shaped electrode is provided on the moving body 40g side, thereby supplying power to the moving body 40g from the guide members 102 to 104.

[0306] Industrial availability

[0307] The crane maintenance system of the present invention is industrially applicable to crane maintenance systems having a moving body that moves around the crane.

[0308] Symbol Explanation

[0309] 20-Crane, 30-Crane terminal (processing unit), 31-Controller, 40-Moving body, 40A-First moving body, 40B-Second moving body, 40a~40g-Moving body, 41-Camera (camera mechanism), 425-Microphone, 426-Temperature sensor, 441-Diagnostic information collection unit, 442-Transmission unit, 44-Control unit, 50-Management server (processing unit), 51-Control device, 511-Diagnostic processing unit, 512-Image processing unit, 513-Display processing unit, 54-Display device, 60, 70-Information terminal, 100-Crane maintenance system, 102~104-Guiding components, 120, 150-Base station, 130-Network, 140-Inspection information database, 160-Customer information database.

Claims

1. A crane maintenance system, comprising: A moving body, equipped with a camera mechanism, moves around a crane with a boom whose pitch angle can be adjusted; and The processing unit performs prescribed processing on the video image data captured by the camera mechanism. The crane maintenance system is characterized in that... The moving body photography includes multiple parts of the crane's maintenance area. The moving body moves to a shooting position based on the pitch angle of the boom detected by sensors on the crane. The processing unit performs the prescribed processing on the video image data of the multiple parts captured by the camera mechanism, thereby enabling maintenance. The specified processing includes any one of the following: Diagnostic procedures are performed to determine whether any abnormalities have occurred in the maintenance areas of the crane based on the camera image data. The crane is created based on multiple camera image data as part of the image data processing. Display processing of the three-dimensional model data to the user or of the video images based on the video image data of the multiple parts captured.

2. The crane maintenance system according to claim 1, characterized in that, The processing unit performs the following processing: processing the camera image data into processed image data suitable for the user to make anomaly judgments; and display processing for displaying the processed image based on the processed image data to the user.

3. The crane maintenance system according to claim 1 or 2, characterized in that, The mobile body sends the camera image data to the crane, and the processing unit collects status information data representing the state of the crane and the camera image data from the crane.

4. The crane maintenance system according to claim 1 or 2, characterized in that, The processing unit determines which customers to send the data to or which customers to allow viewing based on customer information data representing the relationship between customers and customers corresponding to each of the cranes, and on status information data representing the status of each of the cranes.

5. The crane maintenance system according to claim 1 or 2, characterized in that, have: The display device outputs status information indicating the crane's status based on the camera image data; Check the information database and associate each inherent construction machine ID among the multiple cranes with the status information; and The customer information database maps multiple construction machine IDs to customer-related information for multiple cranes. The display device, referencing the customer in the customer information database and the user of the display device, can display the status information of the crane corresponding to multiple construction machine IDs associated with the customer, based on the inspection information database.

6. The crane maintenance system according to claim 1 or 2, characterized in that, The mobile body is capable of flight. During the flight of the mobile body, if the boom of the crane rotates by pitching and the position of the maintenance section of the crane moves, The movable body changes and moves the maintenance part according to the rotation angle of the boom.

7. The crane maintenance system according to claim 1 or 2, characterized in that, The mobile body includes: The first moving body photographs the first area of ​​the crane; and The second moving body photographs a second area of ​​the crane that is different from the first area.

8. The crane maintenance system according to claim 1 or 2, characterized in that the moving body comprises: A first moving body having the camera mechanism; and The second moving body has sensors that are different from those of the camera.

9. The crane maintenance system according to claim 1 or 2, characterized in that, The moving body moves along a guide component provided on the crane. The guide component is disposed on the inner side of the boom of the crane, and the moving body moves on the inner side of the boom.

10. A crane having a boom with a changeable pitch angle that can be serviced by the crane maintenance system of claim 1, characterized in that... The boom has a guide component that physically restricts the movement of the movable body and supports the movable body equipped with a camera mechanism to travel or fly along the guide component, so that the camera mechanism is positioned overlapping with the boom when viewed from a direction perpendicular to the length direction of the boom. The crane has a sensor that detects the pitch angle of the boom in order to determine the shooting position of the moving body.

Images