A control system and method for an intelligent hoist

Abstract

This invention discloses a control system and method for an intelligent lifting device in the field of engineering machinery technology. The method includes: receiving the real-time tilt angle value of the hoisting vehicle and the tension value between the boom and the lifting ring; analyzing the current tilt state of the hoisting vehicle based on the real-time tilt angle value and optimizing the control parameters of the corresponding luffing cylinder control valve; driving the luffing cylinder to level the hoisting vehicle based on the optimized control parameters of the luffing cylinder control valve; determining whether the tension value exceeds a set threshold during the lifting process, and outputting an alarm command in response to a signal indicating that the tension value exceeds the set threshold; otherwise, no action is taken. This invention receives the real-time tilt angle value of the hoisting vehicle through a controller, automatically adjusts the leveling strategy, matches the control parameters, and controls the corresponding luffing cylinder until the hoisting vehicle is automatically leveled. This greatly reduces the labor intensity and rescue time required for operators at the rescue site to repeatedly adjust the length of the lifting rope, thus improving rescue efficiency.

Description

Technical Field

[0001] This invention relates to a control system and method for an intelligent hoisting machine, belonging to the field of engineering machinery technology. Background Technology

[0002] Railway transportation is the main artery of the national economy. With the remarkable progress made in my country's railway construction, especially high-speed passenger railways, the accident situation encountered in railway transportation has become more complex, and the efficiency of rescue needs to be improved.

[0003] For rescue operations involving derailed, tilted, or overturned railway locomotives, rail cranes can be used for lifting and repositioning. However, this operation primarily relies on the locomotive's own weight for lifting and leveling, which involves changing the lifting points of the lifting equipment or the length of the lifting ropes to ensure the locomotive's center of gravity is in the correct position. This reduces rescue efficiency and increases the workload of rescue personnel. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a control system and method for intelligent hoisting equipment. The controller receives the real-time tilt angle value of the hoisting vehicle, and the automatic leveling strategy matches the control parameters to control the corresponding luffing cylinder action until the hoisting vehicle is automatically leveled. This greatly reduces the labor intensity and rescue time required for operators at the rescue site to repeatedly adjust the length of the hoisting rope, and improves rescue efficiency.

[0005] To achieve the above objectives, the present invention is implemented using the following technical solution:

[0006] In a first aspect, the present invention provides a control method for intelligent hoisting equipment, comprising:

[0007] Receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring;

[0008] Based on the analysis of the current tilt state of the hoisting locomotive using real-time tilt angle values, the control parameters of the corresponding luffing cylinder control valve are optimized.

[0009] The luffing cylinder is driven by the optimized control parameters of the luffing cylinder control valve to level the hoisted locomotive.

[0010] During the lifting process, the system determines whether the tension value exceeds the set threshold. If the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken.

[0011] Furthermore, the real-time tilt angle value is detected by a wireless dual-axis tilt sensor installed on the hoisting locomotive, and the wireless dual-axis tilt sensor communicates with the controller through a gateway.

[0012] Furthermore, the wireless dual-axis tilt sensor is powered by its own power supply or by an external power supply, and is detachably fixed to the hoisting locomotive.

[0013] Furthermore, the tension value is detected by a tension sensor installed between the boom and the lifting ring, and there are two tension sensors.

[0014] Furthermore, based on the analysis of the current tilt state of the hoisting locomotive using real-time tilt angle values, the control parameters of the corresponding luffing cylinder control valves are optimized, including:

[0015] By combining the pre-defined X and Y axis directions of the coordinate system with the positive and negative tilt angles α1 and β1 in the real-time tilt angle values, control parameters are output to the corresponding control valves to update the tilt angle.

[0016] Obtain the updated positive and negative tilt angles α2 and β2 in the X and Y axis directions;

[0017] Determine whether α1-α2, α2-α1, β1-β2, and β2-β1 tend to 0;

[0018] In response to signals that α2-α1 or β1-β2 tend to 0, optimize the control parameters of the single-sided variable amplitude cylinder control valve;

[0019] In response to a signal that α1-α2 or β2-β1 tends to 0, optimize the control parameters of the control valve of the variable amplitude cylinder on the other side;

[0020] A warning command is issued in response to signals that α1-α2, α2-α1, β1-β2, and β2-β1 do not tend to 0.

[0021] Furthermore, based on the optimized control parameters of the luffing cylinder control valve, the luffing cylinder is driven to level the hoisted locomotive, including:

[0022] The optimized control parameters of the luffing cylinder control valve are continuously output until the tilt angle of the hoisting locomotive approaches 0.

[0023] In response to the signal that the tilt angle of the hoisting locomotive has not changed to 0 after the control parameter of the single-sided hydraulic cylinder luffing cylinder control valve reaches the limit value, the control parameter of the other side single-sided hydraulic cylinder control valve is matched.

[0024] In response to the signal that the tilt angle of the hoisting locomotive has not changed to 0 after the control parameter of the single-sided luffing cylinder control valve on the other side reaches the limit value, a warning command is issued.

[0025] Furthermore, the control parameters include the control voltage value and the control slope value.

[0026] Secondly, the present invention provides a control system for an intelligent hoisting machine, comprising:

[0027] Data receiving module: used to receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring;

[0028] Control parameter optimization module: used to optimize the control parameters of the corresponding luffing cylinder control valve after analyzing the current tilt state of the hoisting locomotive based on the real-time tilt angle value;

[0029] Leveling module: Used to drive the luffing cylinder to level the hoisted locomotive based on the optimized control parameters of the luffing cylinder control valve;

[0030] Monitoring module: Used to determine whether the tension value exceeds the set threshold during the lifting process of the spreader. In response to the signal that the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken.

[0031] Thirdly, the present invention provides a control device for intelligent hoisting machinery, including a processor and a storage medium;

[0032] The storage medium is used to store instructions;

[0033] The processor is configured to operate according to the instructions to perform the steps of the method according to any of the foregoing.

[0034] Fourthly, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of any of the methods described above.

[0035] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0036] This invention provides a control system and method for intelligent lifting equipment. The controller receives the real-time tilt angle of the lifting vehicle and automatically adjusts the leveling strategy to match control parameters, controlling the corresponding luffing cylinders until the lifting vehicle is automatically leveled. This control system and method significantly reduces the labor intensity and rescue time required for operators to repeatedly adjust the lifting rope length, thus improving rescue efficiency. Furthermore, this invention monitors the load on both sides of the lifting ropes using tension sensors on both sides of the lifting equipment and monitors the overall torque of the lifting equipment through a torque protection system, providing protection and issuing alarms for the lifting operation. This avoids dangerous situations such as exceeding the overall lifting torque limit or exceeding the load limit on one side of the lifting rope, ensuring the safety of the rescue equipment. Attached Figure Description

[0037] Figure 1 This is a diagram of the intelligent lifting device system provided in Embodiment 1 of the present invention;

[0038] Figure 2 This is a flowchart of the intelligent lifting device control system provided in Embodiment 1 of the present invention;

[0039] Figure 3 This is a flowchart of the automatic hoisting and leveling strategy provided in Embodiment 1 of the present invention. Detailed Implementation

[0040] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0041] Example 1:

[0042] This embodiment provides a control method for intelligent lifting equipment. By establishing a communication gateway, real-time angle signals from tilt sensors are transmitted point-to-point to the controller. The controller analyzes the current tilt state of the hoisted vehicle based on the acquired real-time tilt angle value and matches the control parameters of the corresponding luffing cylinder control valve to achieve automatic leveling of the hoisted vehicle. During the lifting operation, the tension of the lifting ropes connected to both sides of the lifting equipment is monitored in real time to assess the load on each side of the rope. If the load exceeds a set threshold, an alarm will sound, eventually leading to a shutdown warning.

[0043] The intelligent lifting device control system provided by this invention involves a lifting device system such as... Figure 1 As shown, the boom 1 and luffing cylinder 2 of the lifting device are distributed on the left and right sides of the plane shown. Under the action of the extension and retraction movement of the luffing cylinder 2, the boom 1 of the lifting device can achieve independent vertical movement on one side of the plane shown. A tension sensor 4 is installed between the boom 1 and the lifting ring 5. The lifting rope is installed at the lifting ring 5 and connected to the hoisting locomotive. Therefore, the load status of the lifting rope on one side can be monitored when the boom 1 is performing lifting operations. The entire lifting device is connected to the hook of the lifting equipment through structure 3, realizing the overall vertical movement of the lifting device on the plane shown.

[0044] Because the locomotive being lifted is an independent, closed system, its own sensors and other information cannot be transmitted to the intelligent control system involved in this invention. Furthermore, even when the locomotive is in normal operation, this intelligent control system cannot install corresponding tilt sensors on the locomotive. Therefore, this invention proposes a control method for detecting the tilt angle of the locomotive being lifted, the process logic of which is as follows: Figure 2 As shown:

[0045] When the intelligent control system involved in this invention is used in the event of a locomotive overturning, the control system includes a wireless dual-axis tilt sensor. This tilt sensor carries its own power supply and can be powered by itself or by an external power source. It can be easily and quickly fixed to the intact body of the locomotive being hoisted.

[0046] The intelligent control system involved in this invention includes a gateway, which can establish a network with the aforementioned wireless dual-axis tilt sensor and controller for information communication.

[0047] The intelligent control system involved in this invention includes a controller that communicates with a wireless dual-axis tilt sensor via the aforementioned gateway, thereby activating the wireless dual-axis tilt sensor to acquire real-time tilt angle values. Based on these tilt angle values, the controller matches the control parameters of the luffing cylinder control valve to achieve independent and accurate movement of the single-sided luffing cylinder of the lifting device, thus completing the lifting and lowering motion of the hoisted locomotive.

[0048] The intelligent control system involved in this invention includes two tension sensors. By communicating with the controller, the load information of the single-sided suspension rope can be transmitted to the controller in real time for monitoring and protection.

[0049] The automatic lifting and leveling strategy involved in this invention is as follows: Figure 3 As shown, after the controller and the wireless dual-axis tilt sensor establish communication via a gateway, the controller will activate the wireless dual-axis tilt sensor. At this time, the wireless dual-axis tilt sensor will transmit the detected real-time tilt angle value of the hoisted locomotive to the controller.

[0050] When the operator selects automatic hoisting, the controller will adopt a trial-and-error hoisting strategy. This involves using the coordinate system set in the controller algorithm, combined with the real-time X-axis tilt angle α1 and Y-axis tilt angle β1 values ​​transmitted by the wireless dual-axis tilt sensors, to output a small voltage value U1 to the corresponding single-sided luffing cylinder control valve F. Subsequently, when the controller detects that the X-axis tilt angle α1 of the hoisted locomotive remains unchanged, it will slowly increase the control voltage value of the single-sided luffing cylinder control valve F at a small slope until the X-axis tilt angle of the hoisted locomotive becomes α2. The value of α2-α1 is calculated. When this value approaches 0, it indicates that the installation coordinate system of the wireless dual-axis tilt sensor coincides with the coordinate system of the controller's automatic leveling algorithm. The control parameters of the corresponding single-sided luffing cylinder control valve, including the control voltage value and control slope value, can be directly matched based on the tilt angle α value of the hoisted locomotive. This continues until the tilt angle α of the hoisted locomotive reaches 0.

[0051] Calculate the value of α2-α1. When this value approaches 0, it indicates that the X and Y axes of the installation coordinate system of the wireless dual-axis tilt sensor are opposite to those of the coordinate system of the controller's automatic leveling algorithm. At this point, the control algorithm will match the control parameters of the single-sided luffing cylinder control valve on the other side, including the control voltage value and the control slope value, according to the tilt angle α value of the hoisted locomotive. This continues until the tilt angle α of the hoisted locomotive reaches 0.

[0052] When the control voltage value of the single-sided luffing cylinder control valve Y is slowly increased at a small slope, the tilt angle α1 in the X-axis direction remains unchanged, but the tilt angle β1 in the Y-axis direction changes to β2. This indicates that the X and Y axes of the installation coordinate system of the wireless dual-axis tilt sensor and the coordinate system of the controller's automatic leveling algorithm are reversed. That is, the X-axis of the installation coordinate system of the wireless dual-axis tilt sensor is the Y-axis of the controller's automatic leveling algorithm, and vice versa. At this time, by calculating the value of β2-β1, the control parameters of the corresponding single-sided luffing cylinder control valve F are matched, including the control voltage value and the control slope value. This continues until the tilt angle β of the hoisted locomotive is 0.

[0053] When the tilt angle α of the hoisted locomotive approaches 0 as the control parameters of the single-sided luffing cylinder continuously move towards 0, but stops changing after the control parameters of the single-sided luffing cylinder control valve F1 reach a certain limit, it indicates that the single-sided luffing cylinder cannot automatically level the hoisted locomotive even when its stroke reaches its limit. At this point, the control algorithm will match the control parameters of the other side's single-sided luffing cylinder control valve F2, including the control voltage and control slope values, causing it to move in the opposite direction until the tilt angle α of the hoisted locomotive reaches 0.

[0054] When both luffing cylinders reach their maximum stroke, if the tilt angle α of the hoisted locomotive is still not 0, the controller will issue an alarm on the display until the machine is shut down for protection.

[0055] After the control parameters of the single-sided luffing cylinder control valve are output, the controller will monitor the load on the lifting ropes on both sides and the overall torque of the lifting device through the tension sensors and torque monitoring system on both sides of the device. If any parameter exceeds the limit, the controller will issue an alarm on the display and eventually shut down the device for protection.

[0056] This invention provides a control system and method for intelligent lifting equipment. By establishing a gateway, the controller can read the tilt angle values ​​detected by wireless dual-axis tilt sensors mounted on the lifting vehicle. Then, based on an automatic leveling strategy, it matches control parameters to control the corresponding luffing cylinders until the lifting vehicle is automatically leveled. This control system and method will significantly reduce the labor intensity and rescue time required for operators at the rescue site to repeatedly adjust the length of the lifting ropes, thus improving rescue efficiency. Furthermore, this invention monitors the load on both sides of the lifting ropes using tension sensors on both sides of the lifting equipment, and monitors the overall torque of the lifting equipment through a torque protection system, providing protection and issuing alarms for the lifting operation. This avoids dangerous situations such as exceeding the overall lifting torque limit or exceeding the load limit on one side of the lifting rope, ensuring the safety of the rescue equipment.

[0057] Example 2:

[0058] A control system for an intelligent hoisting machine, capable of implementing the control method for an intelligent hoisting machine as described in Embodiment 1, includes:

[0059] Data receiving module: used to receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring;

[0060] Control parameter optimization module: used to optimize the control parameters of the corresponding luffing cylinder control valve after analyzing the current tilt state of the hoisting locomotive based on the real-time tilt angle value;

[0061] Leveling module: Used to drive the luffing cylinder to level the hoisted locomotive based on the optimized control parameters of the luffing cylinder control valve;

[0062] Monitoring module: Used to determine whether the tension value exceeds the set threshold during the lifting process of the spreader. In response to the signal that the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken.

[0063] Example 3:

[0064] This invention also provides a control device for an intelligent hoisting machine, which can implement the control method for an intelligent hoisting machine described in Embodiment 1, including a processor and a storage medium;

[0065] The storage medium is used to store instructions;

[0066] The processor is configured to operate according to the instructions to perform the steps of the following method:

[0067] Receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring;

[0068] Based on the analysis of the current tilt state of the hoisting locomotive using real-time tilt angle values, the control parameters of the corresponding luffing cylinder control valve are optimized.

[0069] The luffing cylinder is driven by the optimized control parameters of the luffing cylinder control valve to level the hoisted locomotive.

[0070] During the lifting process, the system determines whether the tension value exceeds the set threshold. If the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken.

[0071] Example 4:

[0072] This invention also provides a computer-readable storage medium that can implement the control method for an intelligent hoisting machine as described in Embodiment 1. The medium stores a computer program that, when executed by a processor, performs the steps of the following method:

[0073] Receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring;

[0074] Based on the analysis of the current tilt state of the hoisting locomotive using real-time tilt angle values, the control parameters of the corresponding luffing cylinder control valve are optimized.

[0075] The luffing cylinder is driven by the optimized control parameters of the luffing cylinder control valve to level the hoisted locomotive.

[0076] During the lifting process, the system determines whether the tension value exceeds the set threshold. If the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken.

[0077] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0078] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0079] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0080] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0081] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A control method for an intelligent hoisting machine, characterized in that, Executed by the controller, including: Receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring; Based on the analysis of the current tilt state of the hoisting locomotive using real-time tilt angle values, the control parameters of the corresponding luffing cylinder control valve are optimized. The luffing cylinder is driven by the optimized control parameters of the luffing cylinder control valve to level the hoisted locomotive. During the lifting process, the system determines whether the tension value exceeds the set threshold. If the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken. The step of optimizing the control parameters of the corresponding luffing cylinder control valve after analyzing the current tilt state of the hoisting locomotive based on real-time tilt angle values ​​includes: Combined with the pre-defined coordinate system in the controller algorithm X, Y In the axial direction and real-time tilt angle values X, Y Positive and negative tilt angles in the axial direction α 1. β 1. Update the tilt angle by outputting control parameters to the corresponding control valve. Get the updated X, Y Positive and negative tilt angles in the axial direction α 2. β 2; judge α 1- α 2. α 2- α 1. β 1- β 2 and β 2- β Does 1 tend towards 0? In response to α 2- α 1 or β 1- β When 2 approaches 0, the control parameters of the single-sided variable amplitude cylinder control valve are optimized according to the controller algorithm; In response to α 1- α 2 or β 2- β When 1 approaches 0, the control parameters of the control valve of the variable amplitude cylinder on the other side are optimized according to the controller algorithm; In response to α 1- α 2. α 2- α 1. β 1- β 2 and β 2- β A warning command is issued when none of the 1s tend towards 0. The step of driving the luffing cylinder to level the hoisted locomotive based on the optimized control parameters of the luffing cylinder control valve includes: The control parameters of the optimized luffing cylinder control valve are continuously output until the tilt angle of the hoisting locomotive approaches 0. When the control parameters of the single-sided hydraulic cylinder luffing cylinder control valve reach the limit value and the tilt angle of the hoisting locomotive has not changed to 0, the control parameters of the single-sided hydraulic cylinder control valve on the other side are matched according to the control algorithm. When the control parameters of the single-sided luffing cylinder control valve on the other side reach their limit values ​​and the tilt angle of the hoisting locomotive has not changed to 0, a warning command is issued.

2. The control method for intelligent hoisting equipment according to claim 1, characterized in that, The real-time tilt angle value is detected by a wireless dual-axis tilt sensor installed on the hoisting locomotive, and the controller communicates with the wireless dual-axis tilt sensor through a gateway.

3. The control method for intelligent hoisting equipment according to claim 2, characterized in that, The wireless dual-axis tilt sensor is powered by its own built-in power supply or by an external power supply, and can be detachably fixed to the hoisting locomotive.

4. The control method for intelligent hoisting equipment according to claim 1, characterized in that, The tension value is detected by a tension sensor installed between the boom and the lifting ring, and there are two tension sensors.

5. The control method for intelligent hoisting equipment according to claim 1, characterized in that, The control parameters include the control voltage value and the control slope value.

6. A control system for an intelligent hoisting machine, used to implement the control method according to any one of claims 1 to 5, characterized in that, include: Data receiving module: used to receive the real-time tilt angle value of the hoisted locomotive and the tension value between the boom and the lifting ring; Control parameter optimization module: used to optimize the control parameters of the corresponding luffing cylinder control valve after analyzing the current tilt state of the hoisting locomotive based on the real-time tilt angle value; Leveling module: Used to drive the luffing cylinder to level the hoisted locomotive based on the optimized control parameters of the luffing cylinder control valve; Monitoring module: Used to determine whether the tension value exceeds the set threshold during the lifting process of the spreader. When the tension value exceeds the set threshold, an alarm command is output; otherwise, no action is taken.

7. A control device for an intelligent hoisting machine, characterized in that, Including processor and storage media; The storage medium is used to store instructions; The processor is configured to operate according to the instructions to perform the steps of the method according to any one of claims 1 to 5.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that, When executed by a processor, the program implements the steps of the method according to any one of claims 1 to 5.

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