A crane cluster synchronous motion control system and control method

Abstract

The present application relates to the technical field of crane control, and especially relates to a crane cluster synchronous motion control system and a control method. The crane cluster synchronous motion control system and the control method provided by the patent are used for synchronous control of lifting positions, absolute value encoders are used for lifting position detection, weight sensors are used for detecting hook weights to determine hook bottom touch signals as the lowest positions of hook lowering, and lifting limit positions installed on the hooks are used as the highest positions of hook lifting, so that correction is performed once at the start of each lifting / descending process, error accumulation is eliminated, and the detection accuracy of positions in the lifting / descending direction is ensured. For transverse movement position control, a UWB positioning base station is used for positioning in the unit, and terminal limit positions are arranged at both ends in the transverse direction, so that the system automatically performs position correction when transverse movement reaches the terminal position, the error in each work cycle is prevented from accumulating, and the transverse movement synchronous accuracy is ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of crane control, in particular to a crane cluster synchronous motion control system and control method. BACKGROUND

[0002] With the continuous development of domestic railways, long rail transportation working conditions are also increasing. The welding rail yard is generally set under the bridge. In the process of laying railway on the bridge, the long rails produced by the welding rail yard need to be transported to the bridge, and then the track laying equipment is used for laying.

[0003] Under normal circumstances, the construction unit will use a long rail transport vehicle to directly transport the long rail to the bridge. However, when the construction site does not have railway and highway transportation conditions, the transportation of long rails will become extremely difficult. In order to solve this problem, a lifting device is needed to directly lift the 300m long rail from under the bridge to the bridge. Because the rigidity of the rail is not large and the length is too long, the synchronization of each lifting point needs to be solved first to ensure that the long rail does not twist, fall, etc. during lifting.

[0004] In the long rail manufacturing plant of the prior art, a plurality of fixed gantry cranes are generally used for lifting operation of the long rail. A distributed control architecture is adopted to control the lifting and traversing speed of each gantry crane through the substation controller installed on each gantry crane, so as to ensure the synchronization of the lifting point position. The position detection sensor used by this type of equipment is usually a code belt position measuring device or an absolute value encoder, and the lifting amount is small, usually only 500mm of lifting is needed to start shifting. Therefore, for the lifting part, the equipment stops control through the signal of descending to the position. This equipment has the following problems when used in railway construction:

[0005] (1) The code belt position measuring device needs to be laid along the span direction during installation. The crane cluster is a cantilever structure, and as the width of the bridge increases, the length of the cantilever will also increase accordingly. When the code belt position measuring device is used, the manufacturing cost will increase significantly, which is not conducive to the cost control of the construction unit.

[0006] (2) The construction site environment is relatively harsh, and it is difficult to regularly maintain the entire traversing track of the equipment. Therefore, slipping between the running wheel and the track is common. When the encoder is used to detect the traversing position, the data needs to be frequently corrected, and the twisting and deformation of the rail caused by the asynchronous equipment is also common.

[0007] (3) The existing equipment generally uses end point position correction for synchronous control of the lifting action, and the synchronization accuracy is low. However, since the rail under the bridge needs to be transported to the bridge, the lifting height needs to exceed the height of the bridge. The lifting height is high and the time is long, so the asynchronization during lifting will cause the twisting or derailing of the rail. Therefore, the lifting synchronization of the lifting point requires a high level of control, and the end point control method cannot be used for lifting synchronization control. SUMMARY

[0008] The technical problem solved by the present application is: for the deficiencies of the prior art, to provide a crane cluster synchronous motion control system and control method, which can ensure the synchronization of the equipment in the lifting process and the terminal position, and can ensure the synchronization accuracy of the transverse position.

[0009] To solve the above technical problems, the technical scheme adopted by the present application is:

[0010] A crane cluster synchronous motion control system for centralized control of the motion of multiple groups of cranes, comprising a master control station and multiple groups of sub-control stations using optical fiber communication;

[0011] The master control station is electrically connected with all sub-control stations, and the master control station is composed of a master station controller, a touch screen and an operating device, the master station controller is used for processing the data collected by each sub-control station and issuing control commands, the touch screen is used for displaying data information in the master station controller, and the operating device includes operating buttons and a wireless remote controller;

[0012] The multiple groups of sub-control stations are respectively electrically connected with multiple groups of cranes, and each group of sub-control station is composed of a sub-station controller, a frequency converter and a sensor device, the sub-control station is used for collecting equipment data of the crane through the sensor and sending it to the master station controller, and the frequency converter is used for controlling the operation of the corresponding motor on the crane according to the control command.

[0013] Further, the master control station is arranged on the bridge deck, the operating buttons are installed on the master station controller cabinet, and the wireless remote controller is held by the on-site operator.

[0014] Further, the multiple groups of sub-control stations are respectively arranged on the multiple groups of crane legs, and the frequency converter includes a lifting frequency converter and a transverse movement frequency converter, which are respectively used for controlling the lifting motor and the transverse movement motor of the corresponding crane;

[0015] The sensor device includes a lifting encoder, a positioning base station, a weight sensor and a limit switch arranged on the crane.

[0016] Further, the lifting encoder is installed on the lifting motor, and specifically uses an absolute value encoder; the weight sensor is installed on the hook, and an upper limit switch is installed at the highest position of the hook.

[0017] Further, the positioning base station is installed on the transverse movement mechanism of the crane, and multiple transverse movement limit switches are installed on the transverse movement track where the transverse movement mechanism is located.

[0018] Further, the lifting motor and the transverse movement motor both use variable frequency motors.

[0019] A crane cluster synchronous motion control method based on the control system as described above, comprising the following steps:

[0020] S1, judging the crane control mode, if it is a manual control mode, executing step S2, if it is an automatic control mode, executing step S3;

[0021] S2, directly controlling the operation of the hoisting motor and the transverse movement motor through the operation button and the wireless remote controller;

[0022] S3, collecting the hoisting operation information and the transverse movement operation information of the crane through the sensor device;

[0023] S4, executing hoisting error correction control according to the hoisting operation information and generating a hoisting control instruction;

[0024] S5, executing transverse movement error correction control according to the transverse movement operation information and generating a transverse movement control instruction;

[0025] S6, the frequency converter controls the running speed of the hoisting motor and the transverse movement motor respectively according to the hoisting control instruction and the transverse movement control instruction.

[0026] Further, in step S3, the hoisting operation information specifically includes: hoisting position information collected by a hoisting encoder, a hook bottom touch signal determined by a weight sensor, and a hook top touch signal determined by a rising limit switch;

[0027] The transverse movement operation information specifically includes: transverse movement position information collected by a position measurement base station, and transverse movement point position information determined by a plurality of transverse movement limit switches.

[0028] Further, in step S4, the hoisting error correction control specifically includes the following steps:

[0029] S41, collecting the hook bottom touch signal by the weight sensor to determine whether the hook is at the actual lowest point;

[0030] S42, when the hook is at the actual lowest point, comparing the hoisting position information collected by the hoisting encoder with the error value of the actual lowest point to determine the descending error;

[0031] S43, adjusting the descending running speed of the hoisting motor according to the descending error;

[0032] S44, collecting the hook top touch signal by the rising limit switch to determine whether the hook is at the actual highest point;

[0033] S45, when the hook is at the actual highest point, comparing the hoisting position information collected by the hoisting encoder with the error value of the actual highest point to determine the ascending error;

[0034] S46, adjusting the lifting operation speed of the lifting motor according to the lifting error.

[0035] Further, in step S5, the lateral movement error correction control specifically comprises the following steps:

[0036] S51, collecting the actual lateral movement point of the lateral movement mechanism of the crane through a plurality of lateral movement limit switches;

[0037] S52, collecting the lateral movement position information of the lateral movement mechanism of the crane through a position measurement base station;

[0038] S53, comparing the error value of the lateral movement position information of the lateral movement mechanism of the crane and the actual lateral movement point to determine the lateral movement error;

[0039] S54, adjusting the operation speed of the lateral movement motor according to the lateral movement error.

[0040] Compared with the prior art, the present application has the following main advantages:

[0041] 1. For lifting position synchronous control, the present application uses an absolute value encoder to detect the lifting position, and a weight sensor to detect the weight of the hook to determine the hook bottom signal as the lowest position of the hook descent, and an upward limit installed on the hook as the highest position of the hook ascent, so that correction is performed at the beginning of each lifting / descending process to eliminate error accumulation and ensure the detection accuracy of the position in the lifting / descending direction;

[0042] 2. For lateral movement position control, the present application uses a UWB positioning base station for positioning, and sets terminal limit switches at both ends of the lateral movement direction, so that the system automatically performs position correction when the lateral movement reaches the terminal position, thereby ensuring that the error does not accumulate within each work cycle and ensuring the lateral movement synchronous accuracy;

[0043] 3. The present application uses a position measurement base station to detect the position, which can avoid the cost increase problem caused by the increase of span when using a code band to measure the position, and also can avoid the precision reduction problem caused by the wheel slipping when using an encoder to measure the position;

[0044] 4. To reduce the starting current and speed control, the lifting and walking of the present application both use frequency conversion control, which controls the motor speed by changing the power supply frequency to achieve the correction effect, and the lifting and walking motors of the electric hoist are all variable frequency motors, which can withstand the constantly changing power supply frequency. BRIEF DESCRIPTION OF DRAWINGS

[0045] Figure 1 It is a whole schematic diagram of the control system of the present application;

[0046] Figure 2 It is a schematic diagram of the main control station of the present application;

[0047] Figure 3 This is a schematic diagram of a sub-control station of the present invention;

[0048] Figure 4 The overall flow chart of the control method of the present invention is

[0049] Figure 5 Flowchart of error correction control of the present invention. DETAILED DESCRIPTION

[0050] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely for the purpose of explaining the present invention and are not intended to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

[0051] It should be pointed out that, according to the needs of implementation, the various steps / components described in this application can be split into more steps / components, or two or more steps / components or partial operations of steps / components can be combined into new steps / components to achieve the purpose of the present invention.

[0052] 1. A crane cluster synchronous motion control system

[0053] like Figure 1 As shown, a crane cluster synchronous motion control system implemented according to the present invention is used to centrally control the motion of multiple groups of cranes, including 1 main control station and 12 sub-control stations. Each sub-control station controls two cranes, and optical fiber is used for data communication between the control stations.

[0054] This solution aims to automate the control of 24 cranes, integrating centralized control, synchronized lifting and traversing, precise positioning, and automatic lifting. Synchronized control ensures the straightness of long rails during lifting, enhancing equipment safety. Centralized control and automated lifting significantly improve construction efficiency, enabling the entire lifting process to be completed by a single operator.

[0055] The overall structure adopts a distributed control structure. Each sub-control station collects data nearby. After the data is uploaded to the main station, the main station will uniformly process the data and send the processing results back to each sub-station. The sub-station will then control the motors and other electrical equipment accordingly based on the processing results of the main station.

[0056] like Figure 2 As shown, the main control station consists of a main station controller (main station PLC), a touch screen and an operating device. The main station controller is used to process the data collected by each sub-control station and issue control commands;

[0057] The touch screen is used to display data information in the host controller in a visual manner such as a table or a graph.

[0058] The operation device includes operation buttons and a wireless remote controller, and the operator can perform operations such as starting / stopping, function switching and action control of the device through the operation buttons, and the wireless remote controller can perform action control such as lifting and transverse movement of the device as an auxiliary operation means.

[0059] As shown in Figure 3 Each sub-control station is composed of a sub-station controller (sub-station PLC), a frequency converter and a sensor device, the sub-control station is used to collect device data of the crane through the sensor and send the data to the host controller, and the frequency converter is used to control the operation of the corresponding motor on the crane according to the control command.

[0060] Further, the host control station is arranged on the bridge deck, the operation buttons are installed on the host controller cabinet, and the wireless remote controller is held by the on-site operator; the multiple sub-control stations are arranged on the multiple crane legs respectively, and the frequency converter includes a lifting frequency converter and a transverse movement frequency converter, which are used to control the lifting motor and the transverse movement motor of the corresponding crane respectively.

[0061] Further, the sensor device includes a lifting encoder, a position measurement base station, a weight sensor and a limit switch arranged on the crane.

[0062] Further, the lifting encoder is installed on the lifting motor and specifically adopts an absolute value encoder; the weight sensor is installed on the hook, and an upper limit switch is installed at the highest position of the hook.

[0063] Further, the position measurement base station is installed on the transverse movement mechanism of the crane, and multiple transverse movement limit switches are installed on the transverse movement track where the transverse movement mechanism is located.

[0064] Further, the lifting motor and the transverse movement motor both adopt variable frequency motors.

[0065] II. A crane cluster synchronous motion control method

[0066] Based on the same inventive concept, the embodiment of the present application also provides a crane cluster synchronous motion control method based on the control system as described above, as shown in Figure 4 The specific steps include the following steps:

[0067] S1, judging the crane control mode, if it is a manual control mode, executing step S2, and if it is an automatic control mode, executing step S3;

[0068] S2, directly controlling the operation of the lifting motor and the transverse movement motor through the operation buttons and the wireless remote controller;

[0069] S3, collecting the lifting operation information and lateral movement operation information of the crane through sensor equipment;

[0070] S4, performing lifting error correction control according to the lifting operation information and generating a lifting control instruction;

[0071] S5, performing lateral movement error correction control according to the lateral movement operation information and generating a lateral movement control instruction;

[0072] S6, the frequency converter controls the operating speeds of the lifting motor and the traverse motor respectively according to the lifting control instruction and the traverse control instruction.

[0073] Furthermore, in step S3, the lifting operation information specifically includes: the lifting position information collected by the lifting encoder, the hook bottoming signal determined by the weight sensor, and the hook top touching signal determined by the rising limit switch; the lateral operation information specifically includes: the lateral position information collected by the positioning base station and the lateral point position information determined by multiple lateral limit switches.

[0074] Furthermore, in step S4, the lifting error correction control specifically includes the following steps:

[0075] S41, collecting the hook bottoming signal through the weight sensor to determine whether the hook is at the actual lowest point;

[0076] S42, when the hook is at the actual lowest point, comparing the lifting position information collected by the lifting encoder with the error value of the actual lowest point to determine the descent error;

[0077] S43, adjusting the descending speed of the hoisting motor according to the descending error;

[0078] S44, determining whether the hook is at the actual highest point through the hook top touch signal collected by the rising limit switch;

[0079] S45, when the hook is at the actual highest point, comparing the lifting position information collected by the lifting encoder with the error value of the actual highest point to determine the lifting error;

[0080] S46, adjusting the ascending speed of the hoisting motor according to the ascending error.

[0081] like Figure 5 As shown, in step S5, the lateral error correction control specifically includes the following steps:

[0082] S51, collecting the actual transverse position of the crane transverse mechanism through multiple transverse limit switches;

[0083] S52, collecting the transverse position information of the crane transverse mechanism through the positioning base station;

[0084] S53, compare the error value of the actual lateral movement point position information of the lateral movement mechanism of the crane with the lateral movement position information, and determine the lateral movement error;

[0085] S54, adjust the running speed of the lateral movement motor according to the lateral movement error.

[0086] In summary:

[0087] 1. For the lifting position synchronization control, the absolute value encoder is used for lifting position detection, and the weight sensor is used for detecting the hook weight to determine the hook bottom signal as the lowest position of the hook descent, and the lifting limit installed on the hook is used as the highest position of the hook ascent, so that the correction is performed at the beginning of each ascent / descent process to eliminate error accumulation and ensure the detection accuracy of the position in the lifting direction;

[0088] 2. For the lateral movement position control, the UWB positioning base station is used for positioning, and the terminal limit is set at both ends of the lateral movement direction, so that the system automatically performs position correction when the lateral movement reaches the terminal position, so that the error in each work cycle does not accumulate, and the lateral movement synchronization accuracy is ensured;

[0089] 3. The position detection is detected by the positioning base station, which can avoid the cost increase problem caused by the increase of span when the code band position detection is used, and can also avoid the precision reduction problem caused by the wheel slipping when the encoder position detection is used;

[0090] 4. In order to reduce the starting current and speed control, the lifting and walking of the patent adopt variable frequency control, which controls the motor speed by changing the power supply frequency to achieve the correction effect, and the lifting and walking motors of the electric hoist are selected as variable frequency motors, which can withstand the constantly changing power supply frequency.

[0091] Those skilled in the art will readily understand that the above description is only a preferred embodiment of the present application, and is not intended to limit the present application, and any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A control method of a crane cluster synchronous motion control system for collectively controlling motions of a plurality of groups of cranes, characterized by: The control system comprises a master control station and multiple sub control stations using optical fiber communication; The master control station is electrically connected with all the sub control stations, and comprises a master controller, a touch screen and operating devices, the master controller is used for processing data collected by each sub control station and issuing control commands, the touch screen is used for displaying data information in the master controller, and the operating devices comprise operating buttons and a wireless remote controller; Each sub control station is electrically connected with multiple cranes, and comprises a sub controller, a frequency converter and sensor devices, the sub control station is used for collecting equipment data of the crane through sensors and sending the data to the master controller, and the frequency converter is used for controlling the operation of corresponding motors on the crane according to the control commands; The control method comprises the following steps: S1, judging the control mode of the crane, if it is a manual control mode, executing step S2, if it is an automatic control mode, executing step S3; S2, directly controlling the operation of the lifting motor and the transverse movement motor through the operating buttons and the wireless remote controller; S3, collecting lifting operation information and transverse movement operation information of the crane through sensor devices; S4, executing lifting error correction control according to the lifting operation information, and generating a lifting control instruction; and each time the lifting / descending process starts, correction is performed once; S5, executing transverse movement error correction control according to the transverse movement operation information, and generating a transverse movement control instruction; and when the crane moves to the terminal position, the system automatically performs position correction, so that the error in each work cycle does not accumulate; S6, the frequency converter controls the running speed of the lifting motor and the transverse movement motor according to the lifting control instruction and the transverse movement control instruction respectively; The lifting operation information specifically comprises lifting position information collected through a lifting encoder, a hook bottom touch signal determined through a weight sensor and a hook top touch signal determined through an ascending limit switch; The transverse movement operation information specifically comprises transverse movement position information collected through a position measurement base station and transverse movement point position information determined through multiple transverse movement limit switches; The lifting error correction control specifically comprises the following steps: S41, collecting the hook bottom touch signal through the weight sensor to determine whether the hook is at the actual lowest point; S42, when the hook is at the actual lowest point, comparing the error value of the lifting position information collected by the lifting encoder with the actual lowest point to determine a descending error; S43, adjusting the descending running speed of the lifting motor according to the descending error; S44, collecting the hook top touch signal through the ascending limit switch to determine whether the hook is at the actual highest point; S45, when the hook is at the actual highest point, comparing the error value of the lifting position information collected by the lifting encoder with the actual highest point to determine an ascending error; S46, adjusting the ascending running speed of the lifting motor according to the ascending error; The transverse movement error correction control specifically comprises the following steps: S51, collecting the actual transverse movement point position of the crane transverse movement mechanism through multiple transverse movement limit switches; S52, collecting the transverse movement position information of the crane transverse movement mechanism through a position measurement base station; S53, compare the error value of the crane transverse movement mechanism transverse position information and the actual transverse point position to determine the transverse error; S54, adjust the running speed of the transverse motor according to the transverse error; The weight sensor is installed on the hook, and the upper limit switch is installed on the highest position of the hook.

2. The control method according to claim 1, characterized by: The main control station is arranged on the bridge deck, the operation button is installed on the main station controller cabinet, and the wireless remote controller is held by the on-site operator.

3. The control method according to claim 1, characterized by: The multi-component control station is arranged on the multiple crane legs, and the frequency converter includes a lifting frequency converter and a transverse movement frequency converter, which are used for controlling the lifting motor and the transverse movement motor of the corresponding crane respectively. The sensor device includes a lifting encoder, a position measurement base station, a weight sensor and a limit switch arranged on the crane.

4. The control method according to claim 3, characterized in that: The lifting encoder is installed on the lifting motor, and specifically adopts an absolute value encoder.

5. The control method according to claim 3, characterized by: The position measurement base station is installed on the transverse movement mechanism of the crane, and multiple transverse movement limit switches are installed on the transverse movement track of the transverse movement mechanism.

6. The control method according to claim 3, characterized by: The lifting motor and the transverse movement motor are both variable frequency motors.

Images