A gantry crane automatic hoisting system and method

Abstract

The present application provides a gantry crane automatic hoisting system and method. The gantry crane automatic hoisting system includes: a trolley mechanism, a crab mechanism, a hoisting mechanism, and a tipping mechanism; the trolley mechanism moves along the direction of the construction track; the crab mechanism moves along the length direction of the crossbeam; the hoisting mechanism drives the spreader to move in the vertical direction; the tipping mechanism cooperates with the hoisting mechanism to flip the muck box; the control systems of the trolley mechanism, the crab mechanism, and the hoisting mechanism are all communicatively connected to the PLC. An absolute encoder is further provided in the trolley mechanism, the crab mechanism, and the hoisting mechanism. The absolute encoder is configured to obtain the three-dimensional position information of the spreader. The PLC is configured to automatically control the movement of the trolley mechanism, the crab mechanism, and the spreader according to the three-dimensional position information; an anti-sway program is further preset in the PLC, and the anti-sway program is configured to automatically adjust the speeds of the trolley mechanism, the crab mechanism, and the spreader according to the three-dimensional position information; the hoisting mechanism further includes a metal flaw detection device for monitoring the state of the wire rope.

Description

Technical Field

[0001] This application generally relates to the technical field of lifting equipment. More specifically, this application relates to a gantry crane automatic lifting system and method. Background Art

[0002] With the development of China's economy, in order to solve the problem of difficult travel in large and medium-sized cities, numerous subway projects have been planned and constructed. During the process of subway track tunneling, a large amount of muck is generated, and a gantry crane mechanism is required to discharge the large amount of muck. Currently, the control of muck discharge by the gantry crane mechanism is usually performed manually. Due to the limited accuracy of manual operation, the muck box is inevitably shaken during loading, unloading, and transportation, resulting in equipment damage or muck spillage.

[0003] Therefore, how to provide a safe and stable gantry crane automatic lifting system and method is an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0004] In view of this, this application provides a gantry crane automatic lifting system that can automatically lift the muck box without manual operation and smoothly unload the muck therein to a designated area. This application also provides a gantry crane automatic lifting method.

[0005] To achieve the above object, the present application provides a gantry crane automatic hoisting system, including: a trolley mechanism, a crab mechanism, a hoisting mechanism, and a tipping mechanism; the trolley mechanism includes a trolley main body and a trolley traveling device; the trolley main body includes columns located on both sides of the construction track and a cross beam spanning the construction track, and the columns and the cross beam are connected to form a portal structure; the trolley traveling device is installed below the columns and is configured to drive the trolley main body to move along the direction of the construction track; the crab mechanism includes a crab main body and a crab traveling device; the crab main body is located above the cross beam of the trolley main body; the crab traveling device is installed between the crab main body and the cross beam and is configured to drive the crab main body to move along the length direction of the cross beam; the hoisting mechanism includes a driving drum, a steel wire rope, and a spreader; the driving drum is installed on the crab main body, the driving drum is connected to the spreader through the steel wire rope, and the driving drum is configured to drive the spreader to move in the vertical direction; the spreader includes a spreader beam, telescopic arms that can extend and retract along both sides of the spreader beam, a hanging plate located below the telescopic arms, and a detection switch arranged in the hanging plate, and lifting lugs matching the hanging plate are arranged on both sides of the muck box to be hoisted; the tipping mechanism includes a tipping hook installed on the crab main body or the spreader beam, and the tipping hook is configured to hook the bottom of the muck box so as to cooperate with the hoisting mechanism to tip the muck box; the control systems of the trolley traveling device, the crab traveling device, and the driving drum are all communicatively connected to a programmable logic controller (PLC), and absolute value encoders are further arranged in the trolley traveling device, the crab traveling device, and the driving drum, and the absolute value encoders are configured to obtain the three-dimensional position information of the spreader, and the PLC is configured to automatically control the movement of the trolley traveling device, the crab traveling device, and the driving drum according to the three-dimensional position information; an anti-sway program is further preset in the PLC, and the anti-sway program is configured to automatically adjust the speeds of the trolley mechanism, the crab mechanism, and the spreader according to the three-dimensional position information; the hoisting mechanism further includes a metal flaw detection device for monitoring the state of the steel wire rope.

[0006] Optionally, vibration monitoring sensors are further arranged in the trolley traveling device, the crab traveling device, and the driving drum.

[0007] Optionally, the main communication network of the gantry crane automatic hoisting system adopts a Modbus-TCP industrial communication network.

[0008] Optionally, the gantry crane automatic hoisting system further includes video monitoring devices arranged around the construction track.

[0009] Optionally, the video monitoring device has a face recognition function and an audio system, and the video monitoring device is configured to issue a warning through the audio system to expel non-staff when it recognizes that they enter the working area.

[0010] Optionally, the absolute value encoder is a multi-turn absolute value encoder.

[0011] Optionally, the spreader is further provided with an electronic scale for weighing the muck box.

[0012] Optionally, the gantry crane automatic lifting system can be operated automatically, semi-automatically or manually.

[0013] Optionally, the metal flaw detection device is a magnetic flaw detection device; the magnetic flaw detection device is placed at the rope outlet below the driving drum, and includes a magnetic memory planning device, a weak magnetic detection device, a follower device and a guide rail; the magnetic memory planning device is configured to apply an external magnetic field to the wire rope, the weak magnetic detection device is configured to detect the magnetic field near the wire rope, and the follower device is configured to drive the magnetic memory planning device and the weak magnetic detection device to swing along with the wire rope on the guide rail when the wire rope swings due to retraction and release.

[0014] The present application also provides a method for loading and unloading slag using the above-mentioned gantry crane automatic lifting system, comprising the following steps: S1, the slag box transport vehicle moves to the loading position and establishes communication with the gantry crane automatic lifting system; S2, the large vehicle body and the small vehicle body move to the loading position; S3, the spreader extends the telescopic arm and lowers it to a preset height; S4, the spreader retracts the telescopic arm to a preset limit position, so that the hanging plate is hung at the lifting ear of the slag box; S5, the spreader rises to the unloading height; S6, the large vehicle body and the small vehicle body move to the unloading position; S7, the flap hook is hung at the bottom of the slag box, and the spreader is lowered to flip the slag box; and S8, reset.

[0015] Compared with the prior art, the gantry crane automatic lifting system and method provided in this application has the following beneficial effects:

[0016] (1) The automatic lifting system for the gantry crane provided in the present application has an absolute encoder installed in the trolley running device, the trolley running device and the driving drum of the lifting mechanism. The absolute encoder can accurately locate the gantry crane itself, the lifting device and the slag box during lifting. The PLC can automatically load, unload and transport the slag box according to the positioning information. The entire slag loading, unloading and transportation process does not require manual operation, which saves manpower and avoids safety accidents caused by manual operation errors.

[0017] (2) The PLC control system is also pre-installed with an anti-sway program, which automatically adjusts the speed of the trolley mechanism, the small car mechanism and the spreader according to the three-dimensional position information fed back by the absolute encoder, so that the slag box will not be shaken during loading, unloading and transportation, which will cause the slag to spill, thereby indirectly improving the slag loading and unloading efficiency; and

[0018] (3) The hoisting mechanism further includes a metal flaw detection device for monitoring the state of the wire rope. The metal flaw detection device is preferably a magnetic flaw detection device. The magnetic flaw detection device can detect the degree of wire rope breakage that is invisible to the naked eye based on the alternating magnetic field generated when scanning the wire rope. When there is a problem with the wire rope, it promptly feedbacks the problem to the staff or the dispatching room, avoiding accidents such as the falling of the hoisted object caused by the direct breakage of the wire rope due to long-term lack of detection or difficulty in visual inspection. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the present application, the embodiments of the present application will be further described and described based on the following drawings. These drawings are only used to more conveniently and specifically describe the embodiments of the present application rather than limit the present application.

[0020] Figure 1 FIG. 9 is a schematic structural diagram of a spreader 100 of a gantry crane automatic hoisting system provided according to an exemplary embodiment of the present application;

[0021] Figure 2 FIG. 13 is a schematic structural diagram of a magnetic flaw detection device 200 provided according to an exemplary embodiment of the present application;

[0022] Figure 3 FIG. 17 is a schematic diagram of the communication relationship of a control system 300 of a gantry crane automatic hoisting system provided according to an exemplary embodiment of the present application; and

[0023] Figure 4 FIG. 21 is a flowchart of a gantry crane automatic hoisting method 400 provided according to an exemplary embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0024] A gantry crane is a hoisting device with a gantry-shaped main beam as the main load-bearing structural member. It spans across the middle position of the construction track and can move along the track. The spreader 100 is suspended on a trolley that can run along the crossbeam of the gantry-shaped main beam, enabling the spreader 100 to achieve vertical lifting and horizontal movement for transporting the lifted objects. For a gantry crane, the positioning accuracy is the basic guarantee of the entire control system. The positioning accuracies of the trolley, the crab, and the hoisting mechanism should be ≤ ±5 mm to achieve the accurate transportation of the lifted objects. The gantry crane automatic hoisting system provided in this application uses positioning sensors installed on the trolley, the crab, and the hoisting mechanism to accurately measure the three-dimensional position information, and sends the measured results to the PLC. The PLC automatically controls the movement of the trolley, the crab, and the hoisting mechanism based on this three-dimensional position information. The drive systems of each mechanism adopt a structure form of PLC combined with an inverter and a network, which is convenient for the PLC to perform real-time and accurate control. In a preferred embodiment of this application, a gantry crane automatic hoisting system is provided, including: a crab mechanism, a trolley mechanism, a hoisting mechanism, and a tipping mechanism; the crab mechanism includes a crab main body and a crab traveling device; the crab main body includes columns located on both sides of the construction track and a crossbeam spanning across the construction track, and the columns and the crossbeam are connected to form a gantry-shaped structure; the crab traveling device is installed below the columns and is configured to drive the crab main body to move along the direction of the construction track; the trolley mechanism includes a trolley main body and a trolley traveling device; the trolley main body is located above the crossbeam of the crab main body; the trolley traveling device is installed between the trolley main body and the crossbeam and is configured to drive the trolley main body to move along the length direction of the crossbeam; the hoisting mechanism includes a driving drum, a wire rope, and a spreader 100; the driving drum is installed on the trolley main body, the driving drum is connected to the spreader 100 through the wire rope, and the driving drum is configured to drive the spreader 100 to move in the vertical direction; the spreader 100 includes a lifting beam 101, telescopic arms 102 that can extend and retract along both sides of the lifting beam 101, a hanging plate 103 located below the telescopic arms 102, and a detection switch 104 arranged inside the hanging plate 103. Lifting lugs matching the hanging plate 103 are arranged on both sides of the muck box to be lifted; the tipping mechanism includes a tipping hook installed on the trolley main body or the lifting beam 101, and the tipping hook is configured to hook the bottom of the muck box to cooperate with the hoisting mechanism to tip the muck box; the control systems of the crab traveling device, the trolley traveling device, and the driving drum are all communicatively connected to the PLC. Absolute encoders are also arranged inside the crab traveling device, the trolley traveling device, and the driving drum, and the absolute encoders are configured to obtain the three-dimensional position information of the spreader 100. The PLC is configured to automatically control the movement of the crab traveling device, the trolley traveling device, and the driving drum according to the three-dimensional position information. In a specific example, a three-axis coordinate system can be established at the construction track site, and absolute encoders are installed inside the crab traveling device, the trolley traveling device, and the driving drum respectively to obtain the three-dimensional position information of the spreader 100. Then the PLC moves the spreader 100 from one specific position to another specific position and performs other operations according to the built-in automatic driving program.For example, the automatic driver can be configured to perform the following series of operations according to the position of the spreader 100, the loading position of the muck box, and the unloading position: move the spreader 100 to the loading position of the muck box, load the muck box, move the spreader 100 together with the muck box to the unloading position, unload the muck in the muck box, and move the muck box back to the loading position of the muck box. The entire gantry crane automatic hoisting system is transformed on the basis of the existing gantry crane hoisting system, adding an automatic operation mode and a semi-automatic operation mode while retaining the original manual operation mode of the traveling crane. The operator can set the operation mode of the gantry crane automatic hoisting system according to the actual situation.

[0025] In a preferred embodiment of the present application, the spreader 100 may have a structure as Figure 1 shown. Refer to Figure 1, the spreader 100 includes a suspension beam 101, telescopic arms 102 that can extend and retract along both sides of the suspension beam 101, a hanging plate 103 located below the telescopic arms 102, and a detection switch 104 provided in the hanging plate 103. Lifting lugs matching the hanging plate 103 are provided on both sides of the muck box, and a driving device connected to the PLC is provided in the spreader 100. When performing a lifting task based on the automatic operation mode or the semi-automatic operation mode, the built-in program of the PLC automatically drives the trolley traveling device and the crab traveling device to move the spreader 100 above the muck box to be loaded, and then performs the lifting operation. When performing the lifting operation, the spreader 100 extends the telescopic arms 102 and lowers them to a preset height so that the hanging plate 103 of the spreader 100 is aligned with the lifting lugs of the muck box. This preset height can be a position preset in advance according to the construction track and the height of the muck box transport vehicle, or a position calculated in real time according to the positioning information of the muck box transport vehicle and the positioning information of the spreader 100; after the hanging plate 103 is aligned with the lifting lugs, the spreader 100 retracts its telescopic arms 102 to a preset limit so that the hanging plate 103 is hooked at the lifting lugs of the muck box; a detection switch 104 is provided in the hanging plate 103, and the detection switch 104 can be used to detect whether the hanging plate 103 cooperates with the lifting lugs, and can also be used to detect whether the spreader 100 is in place at the loading position; after the hanging is completed, the spreader 100 rises to the unloading height, and then the trolley main body and the crab main body move to the unloading position; when unloading the muck, the tipping mechanism drives the muck box to tip. In a preferred embodiment of the present application, the tipping mechanism includes a tipping hook and a tipping hook driving device installed on the trolley main body or the suspension beam 101, and the tipping hook driving device is also connected to the PLC and controlled by it. Before performing the muck unloading operation, first drive the tipping hook to hook at the bottom of the muck box; during the muck unloading operation, drive the spreader 100 to lower and drive the tipping hook to pull the bottom of the muck box in the opposite direction of the muck dumping, then the muck box can be tipped to unload the muck. In a specific embodiment of the present application, the tipping hook can be a hydraulic transverse moving hook installed on the trolley main body. When the spreader 100 lifts the muck box, the hydraulic transverse moving hook is moved away in advance to avoid colliding with the muck box so that the muck box can be smoothly lifted. When the bottom of the muck box is higher than the hydraulic transverse moving hook, the lifting can be stopped, and then the hydraulic transverse moving hook is moved back to the bottom of the muck box, and the muck box is lowered so that the hydraulic transverse moving hook is hooked at the bottom of the muck box (a hanging cross bar matching the hydraulic transverse moving hook is provided at the bottom of the muck box), and then the muck box can rotate and dump soil with the hydraulic transverse moving hook as the hinge point. In an alternative embodiment of the present application, the tipping mechanism can be an automatic hydraulic hanging bucket mechanism provided at the bottom of the muck box, which establishes communication with the gantry crane PLC and cooperates with the spreader 100 to automatically drive the muck box to tip when muck needs to be unloaded. In other embodiments, the tipping mechanism can also be any mechanism known in the art that can drive the muck box to tip. In a preferred embodiment of the present application, the spreader 100 is also provided with an electronic scale for weighing the muck box.When the hoisting load reaches 90% of the rated lifting capacity, the electronic scale can emit a prompt warning signal. When the hoisting load reaches 105% of the rated lifting capacity, the hoisting mechanism will stop running with a time delay. When the hoisting load reaches 110% of the rated lifting capacity, the hoisting power supply will be immediately cut off, thus further ensuring construction safety. In an alternative embodiment of the present application, the spreader 100 may not have a telescopic structure, but a conventional sling and hook structure. The hoisting method of this structure is different from that of the telescopic structure, and this hoisting method will be described in detail in the following gantry crane automatic hoisting method.

[0026] In a preferred embodiment of the present application, the absolute encoder is a multi-turn absolute encoder. The multi-turn absolute encoder has a large measurement range and does not require zeroing, and the sensor accuracy can reach 0.1 mm. In a specific embodiment of the present application, the same type of positioning system can be installed on the trolley mechanism, the crab mechanism and the hoisting mechanism. For example, the trolley mechanism, the crab mechanism and the hoisting mechanism all use multi-turn absolute encoders for positioning. In a specific embodiment of the present application, different types of positioning systems can be installed on the trolley mechanism, the crab mechanism and the hoisting mechanism. For example, the trolley mechanism and the crab mechanism use multi-turn absolute encoders for positioning while the hoisting mechanism uses a wire-pulling encoder for positioning; or, the trolley mechanism and the crab mechanism use a coded scale positioning system for positioning while the hoisting mechanism uses an absolute encoder for positioning. The reader of the coded scale positioning system reads the coded scale by means of infrared opposed light, so as to obtain absolute position information. The coded scale positioning system does not require a reference point and can calculate the position value without time delay. The position data of the coded scale positioning system is made on a stainless steel coded scale through a special coding and perforation process. The coded scale is installed parallel to one side of the track, so that a specific position value can be assigned to each position point of the trolley and crab tracks. In another exemplary embodiment, the positioning system installed on the trolley mechanism, the crab mechanism and the hoisting mechanism can be a laser distance sensor. In yet another exemplary embodiment, the trolley mechanism and the crab mechanism can use a Gray bus positioning system. It should be understood that those skilled in the art can select the positioning methods for each dimension suitable for the gantry crane automatic hoisting system according to the actual requirements of the construction site.

[0027] In a preferred embodiment of the present application, an anti-sway program is also pre-set in the PLC. The anti-sway program is configured to automatically adjust the speeds of the trolley mechanism, the crab mechanism, and the spreader 100 according to the three-dimensional position information. When the automatic or semi-automatic operation mode of the gantry crane automatic lifting system provided by the present application is selected, the speeds of the trolley, the crab, and the hoisting mechanism will no longer be obtained according to the rated output frequency of the frequency converter. Instead, after automatically or manually setting information such as the starting and ending points, restricted area information, and maximum speed and acceleration of the traveling device, the anti-sway program automatically calculates and outputs the set speeds of the trolley, the crab, or the hoisting mechanism to ensure that there will be no excessive sway during the lifting process. In a more preferred embodiment, the anti-sway program also has a control mode combining feedforward and feedback. In the control mode combining feedforward and feedback, an angle-of-sway measuring device also needs to be installed on the hoisting mechanism to estimate the angle of sway during the operation of the spreader 100 based on soft measurement technology. In this mode, first, the predetermined speeds of each traveling device are set in a feedforward manner based on the above-mentioned starting and ending points, restricted area information, maximum speed and acceleration of the traveling device, etc. Then, in a feedback manner, during the operation of the spreader 100, the output frequency of the traveling device frequency converter is adjusted according to the real-time position, speed, and angle of sway, and then the actual operating speed of the traveling device is controlled to achieve the purpose of suppressing the sway of the spreader 100. In a specific embodiment of the present application, the anti-sway program can ensure that the sway amount of the spreader 100 during operation is less than 30 mm, and it stops swaying within 3 swing cycles after stopping. In a preferred embodiment of the present application, a trajectory planning program is also pre-set in the PLC, and an obstacle detection device for identifying the positions of obstacles is correspondingly installed throughout the track construction site. After automatically or manually setting the starting and ending points of the spreader 100 operation, if an obstacle is detected in the operation path, the trajectory planning program automatically plans a new operation path, and the PLC automatically sets the operation parameters of the spreader 100 according to the new operation path. Further, the trajectory planning program and the detection of obstacles can be executed in real time. During the automatic operation of the spreader 100, the obstacle detection results on the operation path can be obtained every once in a while. If there is an obstacle, the operation is suspended and the path is re-planned, so as to achieve a more intelligent obstacle avoidance function and ensure the safety of the equipment and construction personnel.

[0028] In a preferred embodiment of the present application, the hoisting mechanism further includes a metal flaw detection device for monitoring the state of the wire rope. As a key component with a huge consumption and high risk in the hoisting equipment, due to complex working conditions and high-load applications, various damages such as broken wires, wear, corrosion, and fatigue will occur to the wire rope of the gantry crane. If the damage accumulates until the wire rope breaks, serious consequences will occur. In a preferred embodiment of the present application, the metal flaw detection device is a magnetic flaw detection device, for example, refer to Figure 2 . Figure 2 is a schematic structural diagram of the magnetic flaw detection device 200 provided according to an exemplary embodiment of the present application, asFigure 2 As shown, the magnetic flaw detection device 200 is installed at the rope outlet below the driving drum, and includes a magnetic memory planning device 201, a weak magnetic detection device 202, a follower device 203 and a guide rail 204. The magnetic memory planning device 201 is used to apply an external magnetic field to the steel wire rope so that a "memory magnetic field" is formed near the steel wire rope. The weak magnetic detection device 202 is used to detect the magnetic field to obtain the loss information of the steel wire rope. The follower device 203 is configured to drive the magnetic memory planning device 201 and the weak magnetic detection device 202 to swing with the steel wire rope on the guide rail 204 when the steel wire rope swings due to retraction and release, so as to prevent the magnetic memory planning device 201 and the weak magnetic detection device 202 from accidentally touching the steel wire rope. Ferromagnetic materials will generate a "memory magnetic field" related to their physical properties under the action of a magnetic field. By detecting the magnetic field to obtain the magnetic energy potential difference information of the steel wire rope, the damage of the steel wire rope can be inferred. A normal steel wire rope will form a stable magnetic field within the detection range of magnetic flaw detection; and when the damaged part passes through the scanning range, an alternating magnetic field will be formed. By using the principle of magnetic flaw detection, the damage state of the wire rope can be detected without disassembling the wire rope. When there is a problem with the wire rope, the metal flaw detection device can promptly feedback the problem to the staff or the dispatch room. In a further preferred embodiment, the metal flaw detection device also includes an image recognition device and an AI visual system. The image recognition device obtains the image of the wire rope, and the AI ​​visual system monitors whether the wire rope is warped, worn, etc. based on the image processing method. The magnetic flaw detection device 200 is combined with the AI ​​visual system to comprehensively monitor the damage of the wire rope in real time and issue alarms related to the damage.

[0029] In a preferred embodiment of the present application, a vibration monitoring sensor is also provided in the trolley running device, the trolley running device and the driving reel. The vibration monitoring sensor monitors the vibration state of the reducer of each driving device, and analyzes whether the current working state of the reducer is in good condition through signal processing. The vibration monitoring sensor ensures that the equipment works well during the entire life cycle, reducing the error rate of manual detection.

[0030] In a preferred embodiment of the present application, the main communication network of the gantry crane automatic lifting system adopts the Modbus-TCP industrial communication network. The system uses wired communication technology to complete the interconnection and communication of system data. Optical fibers and vehicle-mounted base stations are respectively installed at the corresponding positions of the construction track and on the intelligent gantry crane to form a wireless and wired communication network. The communication system is connected to the monitoring center through optical fibers to ensure the stable and reliable transmission of system data, and ensure the real-time and rapidity of data transmission. In a preferred embodiment of the present application, the PLC control system 304 is further connected to the upper-level MES system 308, and the upper-level MES system 308 schedules and manages the database of one or more gantry cranes on site. The gantry crane automatic lifting system real-time feeds back the three-dimensional space coordinates of the spreader 100 during operation through an encoder and real-time adjusts the running speed of the spreader 100, and feeds back the execution completion result after loading and unloading. Refer to Figure 3 , Figure 3 is a schematic diagram of the communication relationship of the control system 300 of the gantry crane automatic lifting system provided according to an exemplary embodiment of the present application. As Figure 3As shown, the absolute value encoder 301 of the trolley traveling device, the absolute value encoder 302 of the crab traveling device, and the absolute value encoder 303 of the driving drum acquire the three-dimensional position information of the spreader 100 and send it to the PLC control system 304. The PLC control system 304 thereby controls the power of the frequency converter 305 of the trolley traveling device, the frequency converter 306 of the crab traveling device, and the frequency converter 307 of the driving drum. The PLC control system 304 is further connected to the upper-level MES system 308 to achieve overall control through the upper-level MES system 308. In a preferred embodiment of the present application, the upper-level MES system 308 is located in the central control room, and its information display system can display various information of the entire gantry crane automatic lifting system, including but not limited to: lifting information: lifting height, crab position, trolley position, lifting weight; distance to target information: lifting height difference, crab position difference, trolley position difference; currently executed actions and status; manual, semi-automatic, and full-automatic mode switching; frequency converter information: current, voltage, direction, speed, temperature, fault code; positioning information: positions of each target point, electronic limit information; fault information: fault code, corresponding solution; operating status of the PLC; communication status of devices on the network; operating status of the driving device; operating status of the control device; analog display of the control circuit, etc. In a preferred embodiment of the present application, the gantry crane automatic lifting system further includes a remote maintenance system, enabling the control system to have the ability to remotely handle faults. When the equipment malfunctions and the on-site personnel cannot eliminate it, it can be remotely connected through the 4G Internet of Things module, and the manufacturer's technical personnel can remotely troubleshoot and maintain the equipment, shortening the repair and troubleshooting time. In a preferred embodiment of the present application, the gantry crane automatic lifting system further includes a fault query and analysis system. Through the fault query and analysis system installed on the industrial computer in the central control room, the operating status and fault status of each crane can be queried in real time, facilitating the management personnel to analyze, query, and solve faults in a timely manner. The content of the fault can be sent to the background database for storage, facilitating the management and analysis by the maintenance personnel.

[0031] In a preferred embodiment of the present application, the gantry crane automatic lifting system further includes a video monitoring device arranged around the construction track. To facilitate the management personnel to monitor the operating status of the equipment in real time, a video monitoring system can be installed in each key area. For example, monitoring points are set in areas such as the pedestrian passage, spreader working area, and trolley running area, and the monitoring data is transmitted to the central control room through the network. Further, the video monitoring device arranged near the gantry working area, especially near the slag pit where slag is temporarily placed, can also have a face recognition function and an audio system. When a non-staff member is recognized to enter the working area, a warning can be issued through the audio system to expel them.

[0032] In a preferred embodiment of the present application, a method for loading and unloading muck using the above gantry crane automatic lifting system is further provided. For example, refer to Figure 4 . As Figure 4 shown, the method includes the following steps: In block 401, the muck box transport vehicle moves to the loading position and establishes communication with the gantry crane automatic lifting system; in block 402, the main trolley body and the main hoist body move to the loading position; in block 403, the spreader 100 extends the telescopic arm 102 and lowers it to a preset height; in block 404, the spreader 100 retracts the telescopic arm 102 to a preset limit, so that the hanging plate 103 is hooked at the lifting lug of the muck box; in block 405, the spreader 100 rises to the unloading height; in block 406, the main trolley body and the main hoist body move to the unloading position; in block 407, the tipping hook hooks the bottom of the muck box, and at the same time the spreader 100 descends to turn over the muck box; and in block 408, reset. Optionally, after the spreader 100 extends the telescopic arm 102 and lowers it to a preset height in block 404, the spreader 100 can be stationary for a period of time to ensure that it no longer shakes, and then the subsequent steps can be executed after the spreader 100 is stable. Optionally, before the spreader 100 rises to the unloading height in block 405, the spreader 100 can be first raised to the detection position, and the detection switch 104 detects whether the spreader 100 is in place, and then the spreader 100 is raised to the unloading height after it is in place. Sensors matching the detection switch 104 are provided at both the muck box and the loading position, and the detection switch 104 can be used to detect whether the hanging plate 103 cooperates with the lifting lug or whether the spreader 100 is at the loading position. In an alternative embodiment of the present application, the spreader 100 may not have a telescopic structure, but a conventional sling hook structure, and the lifting method of this structure is different from that of the telescopic structure. For example, the method may include: S1, the muck box transport vehicle moves to the loading position and establishes communication with the gantry crane automatic lifting system; S2, move the main trolley to the loading position; S3, move the hoist to about 20 cm in front of the muck box; S4, lower the spreader 100 to the height of the muck box, so that the hook of the spreader 100 is lower than the lifting lug of the muck box; S5, move the hoist to the position of the muck box; S6, lift the spreader 100 until the hook is hooked on the lifting lug of the muck box; S7, detect whether the hook and the lifting lug can be firmly hooked; S8, lift the muck box to the unloading height; S8, move the main trolley and the hoist to the unloading position; S9, the tipping hook hooks the bottom of the muck box, and at the same time the spreader 100 descends to turn over the muck box; and S10, reset. The gantry crane automatic lifting system and method provided in the present application can adopt spreaders 100 with different structures including the prior art, and adjust the automatic lifting program according to the structure of the spreader 100.

[0033] It should be understood that the structures and / or methods in the various embodiments provided in the present application can be combined, modified and / or changed to form new technical solutions. Without creative labor, these technical solutions should also be included in the scope of protection required by the present application.

[0034] Numerous specific examples are provided in the embodiments presented herein. It should be understood that these examples are only for a detailed elaboration of the embodiments of the present application and not a limitation of the present application. The embodiments of the present application can be practiced without these specific examples. In some embodiments, methods, structures, and / or technologies well known to those skilled in the art are not shown in detail so as not to obscure the understanding of the present application.

[0035] Although the preferred embodiments of the present application have been shown and described herein, it is readily understood by those skilled in the art that these embodiments are provided by way of example only. Those skilled in the art will envision various variations, changes, and alternatives without departing from the present application. It should be understood that the various alternatives described herein for the embodiments of the present application are optionally used to implement the present application. It is intended to define the scope of the present application by the claims and thereby cover the methods and structures within the scope of these claims and their equivalents.

Claims

1. A gantry crane automatic hoisting system, characterized in that, Including: A gantry mechanism, a trolley mechanism, a hoisting mechanism and a tipping mechanism; The gantry mechanism includes a gantry main body and a gantry traveling device; the gantry main body includes columns located on both sides of the construction track and a cross beam spanning the construction track, and the columns and the cross beam are connected to form a portal structure; the gantry traveling device is installed below the columns and is configured to drive the gantry main body to move along the direction of the construction track; The trolley mechanism includes a trolley main body and a trolley traveling device; the trolley main body is located above the cross beam of the gantry main body; the trolley traveling device is installed between the trolley main body and the cross beam and is configured to drive the trolley main body to move along the length direction of the cross beam; The hoisting mechanism includes a driving drum, a steel wire rope and a spreader (100); the driving drum is installed on the trolley main body, the driving drum is connected to the spreader (100) through the steel wire rope, and the driving drum is configured to drive the spreader (100) to move in the vertical direction; the spreader (100) includes a spreader beam (101), telescopic arms (102) that can expand and contract along both sides of the spreader beam (101), a hanging plate (103) located below the telescopic arms (102), and a detection switch (104) provided in the hanging plate (103), and lifting lugs matching the hanging plate (103) are provided on both sides of the muck box to be hoisted; The tipping mechanism includes a tipping hook installed on the trolley main body or the spreader beam (101), and the tipping hook is configured to hook the bottom of the muck box so as to cooperate with the hoisting mechanism to tip the muck box; The control systems of the gantry traveling device, the trolley traveling device and the driving drum are all communicatively connected to the PLC. Absolute value encoders are also provided in the gantry traveling device, the trolley traveling device and the driving drum. The absolute value encoders are configured to obtain the three-dimensional position information of the spreader (100), and the PLC is configured to automatically control the movement of the gantry traveling device, the trolley traveling device and the driving drum according to the three-dimensional position information; An anti-sway program is also preset in the PLC, and the anti-sway program is configured to automatically adjust the speeds of the gantry mechanism, the trolley mechanism and the spreader (100) according to the three-dimensional position information; and The hoisting mechanism further includes a metal flaw detection device for monitoring the state of the steel wire rope.

2. The gantry crane automatic hoisting system according to claim 1, wherein Vibration monitoring sensors are also provided in the gantry traveling device, the trolley traveling device and the driving drum.

3. The gantry crane automatic hoisting system according to claim 1, wherein The main communication network of the gantry crane automatic hoisting system adopts a Modbus-TCP industrial communication network.

4. The gantry crane automatic hoisting system according to claim 1, characterized in that, It further includes a video monitoring device provided around the construction track.

5. The gantry crane automatic hoisting system according to claim 4, characterized in that, The video monitoring device has a face recognition function and an audio system, and the video monitoring device is configured to issue a warning through the audio system to expel non-staff when it recognizes that they enter the working area.

6. The gantry crane automatic hoisting system according to claim 1, wherein The absolute value encoder is a multi-turn absolute value encoder.

7. The gantry crane automatic hoisting system according to claim 1, characterized in that, The spreader (100) is further provided with an electronic scale for weighing the muck box.

8. The gantry crane automatic hoisting system according to claim 1, characterized in that, The gantry crane automatic hoisting system can operate automatically, semi - automatically or manually.

9. The gantry crane automatic hoisting system according to claim 1, wherein, The metal flaw detection device is a magnetic flaw detection device; The magnetic flaw detection device is arranged at the rope - releasing position under the driving drum, and includes a magnetic memory planning device (201), a weak magnetic detection device (202), a follower device (203) and a guide rail (204); The magnetic memory planning device (201) is configured to apply an external magnetic field to the steel wire rope, the weak magnetic detection device (202) is configured to detect the magnetic field near the steel wire rope, and the follower device (203) is configured to drive the magnetic memory planning device (201) and the weak magnetic detection device (202) to swing along with the steel wire rope on the guide rail (204) when the steel wire rope swings due to retracting and releasing.

10. A method for loading and unloading construction waste by using the gantry crane automatic hoisting system according to any one of claims 1-9, characterized in that, It includes the following steps: S1, the muck box transport vehicle moves to the loading position and establishes communication with the gantry crane automatic hoisting system; S2, the main trolley body and the main hoist body move to the loading position; S3, the spreader (100) extends out of the telescopic arm (102) and descends to a preset height; S4, the spreader (100) retracts into the telescopic arm (102) to a preset limit position, so that the hanging plate (103) is hooked at the lifting lug of the muck box; S5, the spreader (100) rises to the unloading height; S6, the main trolley body and the main hoist body move to the unloading position; S7, the tipping hook is hooked at the bottom of the muck box, and at the same time the spreader (100) descends to tip the muck box; and S8, reset.

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