Crane automation control method and crane automation control system

Abstract

This application relates to the field of automation control technology, specifically disclosing a crane automation control method and a crane automation control system. The crane automation control method is applied to a crane automation control device in a crane automation control system, wherein the crane automation control device stores multiple functional control programs. The method includes: receiving a crane device type and an execution instruction; calling a corresponding functional control program based on the device type and the execution instruction as a control program; and running the control program to control the crane to perform the operation corresponding to the execution instruction. Through the above-mentioned methods, this application can improve the degree of crane automation control, streamline the automation control architecture, and facilitate subsequent maintenance.

Description

Technical Field

[0001] The present application relates to the field of automation control technology, and in particular to a crane automation control method and a crane automation control system. Background Art

[0002] There are many types of cranes, and there are multiple types of equipment. The current crane automation control system cannot achieve control compatibility for each type of equipment. For different types of cranes, a complete set of control programs needs to be set up separately, resulting in a low degree of crane automation control and greater difficulty and cost in subsequent program maintenance. Summary of the Invention

[0003] The present application provides a crane automation control method and a crane automation control system, which can improve the degree of crane automation control, streamline the automation control architecture, and facilitate subsequent maintenance.

[0004] In order to solve the above technical problems, the technical solution adopted in this application is: to provide a crane automation control method, which is applied to a crane automation control device in a crane automation control system. The crane automation control device stores multiple function control programs. The method includes: receiving the equipment type and execution instructions of the crane; calling the corresponding function control program based on the equipment type and the execution instruction as the control program; running the control program to control the crane to perform the operation corresponding to the execution instruction.

[0005] In order to solve the above technical problems, another technical solution adopted in this application is: to provide a crane automation control system, including a crane automation control device and a central control server that are connected to each other for communication, the central control server is used to send execution instructions to the crane automation control device, and the crane automation control device is used to implement the crane automation control method in the above technical solution.

[0006] Through the above scheme, the beneficial effects of the present application are: calling the corresponding functional control program according to the device type and the execution instruction as the control program, and then running the control program to control the crane to perform the operation corresponding to the execution instruction; by modularizing the various control programs in the automation control process according to their functions, and then calling the corresponding functional control program according to different device types and execution instructions to perform the corresponding control operations, the control framework can be greatly simplified, and the control framework can be made compatible with various device types, thereby improving the degree of automation control of the crane and facilitating subsequent program maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without inventive efforts. Among them:

[0008] Figure 1 This is a structural diagram of an embodiment of a crane automation control system provided by the present application;

[0009] Figure 2 This is a structural diagram of another embodiment of the crane automation control system provided by the present application;

[0010] Figure 3 This is a flow chart of an embodiment of the storage yard management system generating execution instructions provided by the present application;

[0011] Figure 4 This is a flow chart of an embodiment of a crane automation control method provided by the present application;

[0012] Figure 5 This is a flowchart of an embodiment of S430 provided by this application;

[0013] Figure 6 This is a flowchart of another embodiment of S430 provided by this application;

[0014] Figure 7 This is a flow chart of an embodiment of the automatic control mode provided by the present application;

[0015] Figure 8 It is a flow chart of an embodiment of the semi-automatic control mode provided by this application. DETAILED DESCRIPTION

[0016] In order to enable those skilled in the art to better understand the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings and embodiments in the embodiments of the present invention. It is particularly noted that the following embodiments are only used to illustrate the present application, but do not limit the scope of the present application. Similarly, the following embodiments are only some embodiments of the present application and not all embodiments. All other embodiments obtained by those of ordinary skill in the art without making creative work are within the scope of protection of this application.

[0017] References to "embodiments" in this application mean that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0018] It should be noted that the terms "first", "second" and "third" in this application are only used for descriptive purposes and should not be understood as indicating or suggesting relative importance or implicitly indicating the number of the indicated technical features. Thus, the features defined as "first", "second" and "third" may explicitly or implicitly include at least one of the features. In the description of this application, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but optionally also includes steps or units that are not listed, or optionally also includes other steps or units that are inherent to these processes, methods, products or devices.

[0019] In order to make the objectives, technical solutions, and advantages disclosed in the embodiments of the present invention more clearly understood, the embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings and embodiments. The acquisition, storage, use, and processing of data in the technical solutions of the embodiments of the present invention comply with the relevant provisions of national laws and regulations. It should be understood that the specific embodiments described herein are only used to explain the embodiments of the present invention and are not intended to limit the embodiments of the present invention.

[0020] See also Figure 1 , Figure 1 This is a schematic diagram of the structure of an embodiment of a crane automation control system 10 provided in this application. The crane automation control system 10 includes a crane automation control device 110 and a central control server 120, which are communicatively connected to each other. The central control server 120 is used to send execution instructions to the crane automation control device 110. The crane automation control device 110 is used to implement a crane automation control method. The crane automation control device 110 can be installed on a corresponding crane to achieve automated control of the crane. The crane automation control method is described in detail in the following embodiments and is not described in detail here.

[0021] In one embodiment, if Figure 2As shown, the crane automation control system 10 may further include a basic electronic control device 130, which is communicatively connected to the crane automation control device 110. The crane automation control device 110 is further configured to execute a control program, generate corresponding control instructions, and transmit them to the basic electronic control device 130. The basic electronic control device 130 is configured to control the operation of at least one operating mechanism of the crane 100 in response to the control instructions. It is understood that the basic electronic control device 130 may be connected to various operating mechanisms in the crane 100 to control the operation of at least one operating mechanism of the crane 100 in response to the control instructions. Specifically, the operating mechanisms of the crane 100 may include a trolley mechanism, a trolley mechanism, a hoisting mechanism, and a spreader and spreader guide plate disposed on the hoisting mechanism. Each of these operating mechanisms is a conventional structure in a crane and will not be described in detail in this application.

[0022] In one embodiment, a block management system (BMS) is running in the central control server 120, and the block management system in the central control server 120 can be used to send execution instructions to the crane automation control device 110. Figure 3 As shown, before the yard management system sends the execution instruction to the crane automation control device 110, it may also include:

[0023] S310: Receive macro instructions sent by the terminal operating system.

[0024] The Terminal Operation System (TOS) can run in the central control server 120 or in other servers different from the central control server 120. It is used to manage the operating tasks of various equipment in the terminal. It can send macro instructions to the yard management system in the central control server 120 to enable the crane 100 to perform corresponding operating tasks, where the macro instructions can be yard container loading, container truck loading or automatic parking, etc. The TOS can be generated in response to actual application needs and is not limited here.

[0025] S320: Check whether the macro instruction is executable.

[0026] In one embodiment, whether the macro instruction is executable can be determined by identifying a check code in the macro instruction, or any conventional check method in the art can be used for check, which is not limited or detailed here.

[0027] S330: When the verification is successful, the macroinstruction is decomposed to obtain an instruction queue.

[0028] If verification is successful, the macro instruction is decomposed to obtain an instruction queue; the instruction queue contains multiple execution instructions arranged in sequence. If verification is unsuccessful, an error message can be fed back to the terminal operating system, and subsequent instruction decomposition and sending operations will not be executed.

[0029] S340: Sending each execution instruction to the crane automation control device in sequence, so that the crane automation control device responds to the execution instructions in sequence, and uses the crane automation control method to control the crane to complete all operations corresponding to the macro instruction.

[0030] In one embodiment, before decomposing the macroinstruction in step S330, the yard management system may first determine whether the macroinstruction is an execution instruction or a setting instruction. An execution instruction is used to instruct the operating mechanism of the crane 100 to operate (e.g., the aforementioned yard container loading and automatic parking), and a setting instruction is used to instruct the crane automation control device 110 to adjust operating parameters or operating modes. For example, operating parameters may include the working range of the crane 100 or the maximum operating speed of the crane 100, and operating modes may include automatic control mode or semi-automatic control mode, which are not described in detail herein. In response to the macroinstruction being an execution instruction, the macroinstruction may be decomposed to obtain an instruction queue, and the execution instructions are sequentially sent to the crane automation control device 110. Taking the macroinstruction being a yard container loading as an example, the yard management system may decompose the macroinstruction into a yard container grabbing instruction and a yard container placing instruction, and sequentially send the execution instructions to the crane automation control device 110. In response to the macro instruction being a setting instruction, the yard management system does not need to decompose the setting instruction. It can receive and send the setting instruction to the crane automation control device 110 in real time, so that the crane automation control device 110 can receive and respond to the setting instruction in real time, thereby completing the setting of operating parameters or switching of operating modes in a timely manner.

[0031] The crane automation control method provided in this application is introduced in detail below.

[0032] See also Figure 4 , Figure 4 This is a flow chart of an embodiment of a crane automation control method provided by the present application, which is applied to a crane automation control device in the above-mentioned crane automation control system. The crane automation control device stores multiple function control programs. The method includes:

[0033] S410: Receive the equipment type of the crane and the execution instruction.

[0034] Receives a crane type and executes a command. Crane types may include, but are not limited to, tire-mounted cranes, rail-mounted cranes, different models of tire-mounted cranes, or different models of rail-mounted cranes, such as a tire-mounted single-jib crane and a tire-mounted double-jib crane. It is understood that the crane type can be determined by configuration parameters set by personnel or by identifying the crane model, and this is not limited here.

[0035] In one embodiment, after receiving an execution instruction from a central control server, a check may be performed to determine whether the execution instruction was sent in error. If the execution instruction was not sent in error, subsequent steps S420 to S430 are executed, and a completion message is fed back to the central control server. If the execution instruction was sent in error, subsequent steps S420 to S430 are not executed, and an error message is fed back to the central control server. It is understood that any conventional verification method in the art may be used for verification, and this is not limited or detailed herein.

[0036] In one embodiment, in the process of executing corresponding control operations in response to execution instructions, the crane automation control device can also generate a complete and cyclic jump mode process based on the instruction execution status of each execution instruction, such as: instruction start, instruction completion or exception jump, so that the upper-level software system can perform task allocation by monitoring the changes in the mode process.

[0037] S420: Calling a function control program corresponding to the device type and the execution instruction as a control program.

[0038] The function control program corresponding to the device type and the execution instruction call is used as the control program. In actual applications, the crane automation control device can be a programmable logic controller (PLC), which is equipped with programs, functions (FCs), function blocks (FBs) and global data blocks (DBs). The program mainly includes seven parts: communication, instructions and modes, motion control, subsystem data processing, file processing, debugging tools and simulation. For convenience or security and confidentiality, some functional logic in the program is encapsulated into functions and function blocks. Global variables are placed in different DBs according to their content. In order to distinguish different equipment types of cranes, two variables, CRANE_TYPE and ARMG_STYLE, can be added to the parameter DB, so that the corresponding functional logic (i.e., the corresponding functional control program) can be called according to different configuration parameters to realize the automatic control of the crane.

[0039] By modularizing the various control programs in the automation control process according to their functions, such as operation control or automatic box alignment functional modules, and then calling the corresponding functional control programs to perform corresponding control operations according to different equipment types and execution instructions, the control framework can be greatly streamlined, and the control framework's compatibility with various equipment types can be improved, thereby improving the degree of crane automation control and facilitating subsequent program maintenance.

[0040] S430: Run the control program to control the crane to perform the operation corresponding to the execution instruction.

[0041] Run the control program to control the crane to perform the operation corresponding to the execution instruction; taking the execution instruction of grabbing a box as an example, running the control program can control the crane to perform the box grabbing operation.

[0042] This embodiment uses a function control program corresponding to the device type and the execution instruction as the control program, and then runs the control program to control the crane to execute the operation corresponding to the execution instruction. By modularizing the various control programs in the automation control process according to their functions, and then calling the corresponding function control program according to different device types and execution instructions to execute the corresponding control operations, the control framework can be greatly simplified, and the control framework can be made compatible with various device types, thereby improving the degree of automation control of the crane and facilitating subsequent program maintenance.

[0043] In one embodiment, the crane automation control device and the basic electronic control device can also be set in the same PLC, such as a Siemens PLC. In other words, the crane automation control function and the basic electronic control function are integrated into the same PLC device. Compared with the existing solution in which the crane automation control device and the basic electronic control device are implemented by different devices, such as the crane automation control device is a B&R PLC and the basic electronic control device is a Siemens PLC, the solution in this embodiment integrates the crane automation control function and the basic electronic control function into the same PLC device, using the Siemens PLC instead of the previous B&R PLC. This facilitates the integration of the crane automation control program and the basic electronic control program, reduces the amount of data forwarding between various devices in the crane automation control system, further streamlines the automation control architecture, improves the efficiency of automation control, and facilitates program debugging and maintenance. It is understandable that the above embodiment only uses the Siemens PLC as an example. In other embodiments, other models of PLCs can also be used, and this is not limited here.

[0044] The following describes in detail the solution for using S420 in the above embodiment: calling the corresponding function control program based on the device type and the execution instruction as the control program, taking the execution instruction as an example, where the execution instruction is to place or grab a box, the device type is tire-type or track-type, and the function control program is selected from one, two, or more of the motion control program, the automatic box alignment program, and the large vehicle correction program. Depending on the device type, the function control program called by the execution instruction is also different, and may include the following:

[0045] 1. When the equipment type is tire-type and the execution instruction is to place or grab a box, in response to the execution instruction, the motion control program, automatic box alignment program and trolley correction program corresponding to the tire crane can be called as the control program.

[0046] 2. When the equipment type is rail-type and the execution instruction is to release the box, the motion control program and automatic box matching program corresponding to the rail-type crane can be called as the control program in response to the execution instruction.

[0047] 3. When the equipment type is rail-type and the execution instruction is to grab a box, the motion control program corresponding to the rail-type crane can be called as the control program in response to the execution instruction.

[0048] It can be understood that when a control program contains two or more functional control programs, during the operation of the control program, the two or more programs can be executed crosswise, simultaneously or sequentially, and can be adaptively adjusted according to the actual operating conditions. The execution order of each program in the control program is not limited here.

[0049] Due to the differences in the operating mechanisms of tire cranes and rail cranes, the operating accuracy of the operating mechanisms of rail cranes and tire cranes is different, and there are some differences in the functional requirements during the automation control process. Therefore, there are also some differences in the automation control programs of the two. For example: due to the low operating accuracy of the trolley of the tire crane, the tire crane needs to set up a trolley correction function, while the rail crane does not need it; the trolley positioning accuracy of the tire crane is low, so the tire crane needs to set up an automatic box alignment function during the process of placing and grabbing boxes to avoid box alignment failure, while the rail crane only needs to enable the automatic box alignment function when placing boxes. It can be seen that the above solution can, on the basis of streamlining the control framework, adaptively select the required functional control programs according to different equipment types, while ensuring the operating accuracy and effect of the crane.

[0050] This embodiment modularizes the various control programs within the automation control process by function, then calls the corresponding function control program based on the crane's equipment type and execution instructions. This unifies the automation control programs for each crane type, streamlining the control framework while improving the applicability of the automation control programs. Compared to existing solutions that require multiple automation control programs to control different crane types, this approach allows for the integration of multiple automation control programs into a single set, significantly reducing program maintenance costs. Furthermore, by adaptively selecting the required function control program based on the crane's equipment type, the streamlined control framework further ensures crane operation accuracy and effectiveness.

[0051] It is understandable that the above embodiments are only described by taking cranes of a certain equipment type and function control programs as examples. In other embodiments, more different function control programs can be set according to actual needs, which is not limited here.

[0052] The following embodiment details the method for executing a control program in response to different control programs to control the crane to execute the operation corresponding to the execution instruction (i.e., S430). The control program may be an operation control program, an automatic container alignment program, or a trolley correction program. The trolley correction program may be any program in the field of automated control that can implement a trolley correction function, and this application does not limit or elaborate on this program.

[0053] In the following, in conjunction with a specific embodiment, the control flow of operation control (ie, step S430 ) when the control programs are respectively an operation control program and an automatic box-matching program will be described in detail.

[0054] First, the control program is described as an operation control program as an example.

[0055] See also Figure 5 , Figure 5 This is a flow chart of an embodiment of S430 when the control program provided by this application is running the control program.

[0056] S4311: Obtain detection information and operation status information.

[0057] Operating status information can include the crane's operating speed and position. The basic electronic control device can collect real-time operating status information from each operating mechanism within the crane. This operating status information can be obtained in real time from the basic electronic control device. Detection information can include target detection information or spreader status information. Target detection information includes the target's location, while spreader status information can include the spreader's location and real-time posture.

[0058] In one embodiment, a crane automation control system may include a target detection system (TDS) mounted on the crane trolley frame. The TDS utilizes 3D laser technology to extract target object location information and accurately determine the spatial position of the target object, wherein the target object may be a container, a container truck, an automated guided vehicle (AGV), or a companion support. It is understood that when the target object is a container truck or AGV, the target object location information may also be extracted by a chassis positioning system (CPS) mounted on the crane trolley frame and beam. The CPS utilizes laser detection technology to detect the position and tilt angle of the container truck or AGV, verify container information on the container truck or AGV, accurately locate the container truck or AGV, and monitor the movement of the container truck or AGV in real time. The CPS transmits the target detection information to the crane automation control system to further implement automated operations.

[0059] In one embodiment, the crane automation control system may also include a spreader detection system (SDS) installed on the crane, which can use optical principles and image processing technology to detect the positions of three fixed light sources on the spreader to obtain the position and real-time posture of the spreader in space, and then generate spreader status information and transmit it to the crane automation control device for realizing the subsequent spreader micro-control function.

[0060] S4312: Generate corresponding control instructions based on the execution instructions, detection information and operation status information.

[0061] Based on the execution instructions, detection information and operation status information, corresponding control instructions are generated. Specifically, control instructions corresponding to each operating mechanism can be generated according to the execution instructions, which include not only the intelligent control of a single operating mechanism, but also the linkage of multiple operating mechanisms and the intelligent control of the interaction of multiple control systems. Among them, there can be linkage between the trolley mechanism and the carriage mechanism. When the height of the lifting mechanism is above the safe height, there can also be linkage between the lifting mechanism and the carriage mechanism and the trolley mechanism. At this time, setting the safe height can play a role in safety and anti-collision protection. The value of the safe height can be set according to actual conditions and is not limited here.

[0062] For example: when the execution instruction is to grab or release a box, it can control the trolley mechanism, car mechanism or lifting mechanism to run to the corresponding target position according to the target position in the target detection information and the current position of the crane, and then perform subsequent grabbing or releasing operations.

[0063] S4313: Based on the detection information, the operating status information and the given operating parameters, the current operating parameter value is calculated.

[0064] The current operating parameter values ​​are calculated based on detection information, operating status information, and given operating parameters. Given operating parameters include maximum operating speed, maximum operating acceleration, and maximum operating distance. Specifically, based on target detection information and the operating position and speed feedback from the basic electronic control device, combined with the given operating speed corresponding to each operating mechanism, the current operating speed of each operating mechanism can be calculated in real time, thereby achieving closed-loop speed control of each operating mechanism and improving the accuracy and efficiency of automated control.

[0065] In one embodiment, given operating parameters for each operating mechanism in a crane can be configured based on the equipment type. For example, if the crane has a double-jib crane with tires and corresponds to two truck lanes, the maximum operating distance of the larger trolley mechanism can be set accordingly. If the crane has a single-jib crane with tires and corresponds to only one truck lane, the maximum operating distance of the smaller trolley mechanism can be set accordingly.

[0066] S4314: Sending a control instruction and a current operating parameter value to a basic electric control device, so that the basic electric control device controls at least one operating mechanism of the crane to operate according to the current operating parameter value in response to the control instruction.

[0067] The control instruction and the current operating parameter value are sent to the basic electric control device, so that the basic electric control device controls at least one operating mechanism of the crane to operate according to the current operating parameter value in response to the control instruction.

[0068] Specifically, when the execution instruction is to place or grab a box, the crane can be judged in response to the execution instruction based on the target detection information and operating status information to determine whether it has reached the target corresponding position; if the crane has reached the target corresponding position, a lifting and lowering instruction is generated, which is used to instruct the crane's lifting mechanism to lower until the sling on the lifting mechanism touches the box, thereby further completing the box placement or grabbing operation. Among them, whether the crane has reached the target corresponding position can be judged based on the current position of the crane's trolley mechanism and the trolley mechanism. When the trolley mechanism and the trolley mechanism reach the specified position, it is determined that the crane has reached the target corresponding position. The specified position can be indicated by the execution instruction based on the actual location of the target object, and is not limited here.

[0069] In one embodiment, before sending control instructions and current operating parameter values ​​to the basic electronic control device, a determination can be made as to whether the height of the crane's hoisting mechanism is greater than a safe height. If the height of the crane's hoisting mechanism is greater than the safe height, the step of sending the control instructions and current operating parameter values ​​to the basic electronic control device is executed. If the height of the crane's hoisting mechanism is not greater than the safe height, the step of sending the control instructions and current operating parameter values ​​to the basic electronic control device is not executed to prevent collisions between devices. In other words, the operation of each operating mechanism is controlled only when the hoisting mechanism's height is greater than the safe height, thereby preventing the hoisting mechanism from being too low and colliding with other equipment. The safe height can be set according to actual conditions and is not limited here.

[0070] For example, in actual applications, in response to an execution instruction to grab or release a container, when the height of the lifting mechanism exceeds the safe height, a command to extend or retract the spreader size can be given to control the spreader size to adjust to the target size. The lifting mechanism can then be further controlled to continue descending until it touches the container, thereby completing the action of grabbing or releasing the container. This avoids the problem of the spreader collided with the container due to the extension or retraction of the spreader when the height of the lifting mechanism is too low. Alternatively, in response to an execution instruction, when the height of the lifting mechanism exceeds the safe height, a control instruction to lower or raise the spreader guide can be given. Generally, when operating on a double 20-foot container on a container truck, a control instruction to raise the spreader guide is required to take into account the gap between the containers to avoid collision with the other 20-foot container on the container truck. In other cases, the spreader guide is generally kept in the lowered state.

[0071] In one embodiment, in response to the spreader on the lifting mechanism landing, a spreader unlocking command or a spreader locking command can also be generated based on the landing signal or the rope loosening signal fed back by the basic electronic control device, so that the basic electronic control device controls the spreader to be unlocked or locked according to the spreader unlocking command or the spreader locking command, and after the spreader unlocking or spreader locking operation is completed, the unlocking feedback signal or the locking feedback signal is fed back to the crane automation control device, so that the crane automation control device determines that the spreader unlocking or locking operation is completed.

[0072] This embodiment uses a basic electronic control device to obtain real-time operational status information from each operating mechanism. In response to execution instructions, based on detection information from a target detection device or a spreader detection device, it generates control instructions and current operational parameter values ​​for each operating mechanism. The corresponding control instructions are then sent to the basic electronic control device, which then controls the operation of each operating mechanism in response to the control instructions, effectively improving the accuracy and efficiency of operational control. Furthermore, when controlling the operation of the operating structure, the safe height of the lifting mechanism is also taken into consideration, which can significantly avoid collisions between devices and improve the safety and stability of operational control.

[0073] The following describes the control program in detail by taking the automatic box-matching program as an example.

[0074] It should be noted that for automatic box alignment, a corresponding spreader is provided on the lifting mechanism of the crane, and the automatic box alignment process is completed in conjunction with the state of the spreader.

[0075] Specifically, see Figure 6 , Figure 6 This is a flow chart of another embodiment of S430 when the control program provided by the present application is an automatic box matching program.

[0076] S4321: Obtain spreader status information and target detection information.

[0077] The spreader status information and target detection information here are the same as those introduced above and will not be repeated here.

[0078] S4322: Based on the spreader status information and the target detection information, a spreader fine-tuning instruction is generated. The spreader fine-tuning instruction is used to instruct the spreader to align with the target object, thereby completing the box alignment operation.

[0079] Based on the spreader status information and target detection information, fine-tuning instructions are generated to align the spreader with the target object, thereby completing the container alignment operation. Specifically, upon receiving the spreader status information, it is processed into real-time deviation data. Then, based on the target detection information and real-time deviation data, closed-loop control of the spreader position and sway protection are implemented, thereby achieving precise and safe container alignment.

[0080] In one embodiment, the inching speed value of the spreader can also be calculated in real time based on the target detection information, the spreader status information and the given operating parameters, and fed back to the basic electronic control device, so that the basic electronic control device controls the spreader to adjust its position at the inching speed, so as to align with the target object, thereby further improving the stability and accuracy of the box.

[0081] It is understood that the control program can also be a linkage of multiple programs. For example, the control program can include a motion control program and an automatic box alignment program. In this case, after the operation control based on the operation control program is completed, the automatic box alignment program can be executed in response to the crane's hoisting mechanism descending to the target height. In other words, in response to a command to release or grab a box, the operation control program described in the above embodiment can first be executed to control the hoisting mechanism to descend to the target height, and then the automatic box alignment program can be executed to control the spreader to align with the target object. Furthermore, if the distance between the spreader position and the target object is within a reasonable error range, indicating that the spreader and the target object are aligned, the hoisting mechanism is controlled to continue descending to the target object to complete the box grabbing or release operation; otherwise, the hoisting mechanism remains at the target height until the spreader position is adjusted to within a reasonable error range. The target height can be a certain height above the target object to facilitate spreader calibration. The specific height value can be customized according to actual conditions and is not limited here. The reasonable error range can also be customized according to actual accuracy requirements and is not limited here.

[0082] In one embodiment, the crane automation control system also includes a Landing Check System (LCS) installed on the crane. This system detects positional deviations between the spreader and the target object, assisting with container alignment and enabling precise automatic container grabbing and placement. The LCS is primarily used to detect container alignment during high-level container stacking. The LCS utilizes a single-point laser to assist with container alignment by installing a laser rangefinder near each of the four corners of the spreader, with the laser pointing vertically downward. During container placement, if the container on the spreader is aligned with the container below, the single-point laser will not detect the container below. If the container corners exceed the allowable deviation range (generally 4 cm), the single-point laser will detect the container below, indicating misalignment. Further fine-tuning of the spreader's position is required. By configuring the LCS to assist with container alignment, the impact of TDS and SDS detection errors on stacking accuracy can be effectively reduced. The allowable deviation range can be customized based on actual accuracy requirements and is not limited here.

[0083] In one embodiment, the crane automatic control method may further include: implementing safety interlock protection for the crane, which specifically includes anti-collision protection and machine and yard protection.

[0084] 1. Anti-collision protection

[0085] When other cranes appear within the safety range of a crane, the operating status information, given operating parameters and operating information of the adjacent cranes are obtained; based on the operating status information, given operating parameters and operating information of the adjacent cranes, the maximum safe speed of the crane is calculated and updated in real time to make the operating speed of the crane lower than the maximum safe speed, thereby avoiding collisions between cranes.

[0086] Specifically, the system obtains the crane's real-time trolley position and speed, as well as the real-time trolley position and speed of the adjacent cranes, along with given operating parameters such as trolley acceleration, maximum trolley speed, and safe trolley distance. An intelligent algorithm then calculates and updates the crane's maximum safe trolley speed in real time to achieve trolley mechanism deceleration and collision avoidance. The trolley position and speed of the adjacent cranes are transmitted directly or indirectly to the crane via the yard block management system or the remote crane control system (RCCS).

[0087] 2. Machine and yard protection

[0088] In one embodiment, the crane automation control system also includes a Loading Collision Prevention System (LCPS) installed on the crane. This system scans the contours of the containers at the current bay in real time, assisting in implementing intelligent soft landing and operational protection functions. Specifically, it combines the gaps between containers reported by the TDS, the container contours at the current bay as determined by the LCPS in real time, and the spreader status information reported by the SDS to implement spreader micro-motion anti-collision protection, such as limiting the spreader's micro-motion range and limiting the lifting speed.

[0089] In one embodiment, a protection function can be added to the verification phase of execution commands sent by the yard management system to reject dangerous commands from the yard management system. Dangerous commands refer to special areas within the operating range, such as refrigerated container racks, calibration racks, or substations. Furthermore, action protection can be added during the operational control process based on actual conditions, such as limiting the micro-movement range of the spreader.

[0090] This embodiment intelligently controls the current crane's operating speed by controlling information exchange between control systems. This effectively and promptly avoids collisions between devices and improves the accuracy of anti-collision protection. Furthermore, the addition of dangerous command recognition and operational action protection further enhances operational control safety.

[0091] In one embodiment, the crane automatic control method may further include implementing abnormal handling for the crane, which specifically includes: monitoring whether the crane has a risk situation or receives fault information; if a risk situation occurs or fault information is received, switching the automatic control mode to a semi-automatic control mode to facilitate operator coordination, or switching to a local maintenance mode to facilitate maintenance by maintenance personnel.

[0092] In automatic control mode, the crane's automated control device responds to execution instructions and automatically completes corresponding control operations without human intervention. In semi-automatic control mode, the crane's automated control device responds to execution instructions and semi-automatically performs corresponding control operations, with some operations requiring human intervention. Local maintenance mode, also known as remote manual mode, requires human maintenance or full manual control.

[0093] Specifically, in automatic control mode, the crane automatic control system can monitor the operating status of the crane in real time. If a risk situation or automatic operation failure occurs, the corresponding fault will be reported and the system will be switched to semi-automatic control mode or local maintenance mode for further processing by the central control personnel. Among them, the risk situation may be a mismatch between position and speed changes or a large error in the detection information. When executing the command to grab or release the container, the corresponding fault can be reported based on the fault information fed back by the TDS and / or SDS and / or the basic electronic control device, and the system will be switched to semi-automatic control mode or local maintenance mode for further processing by the central control personnel. Among them, the fault information can be generated in response to the existence of safety hazards and fault conditions that affect automatic operation control. Such fault conditions may be the operation of the operating mechanism is not allowed, the spreader is overloaded, the spreader is unevenly loaded, the target height does not match, or the container gap is too small, which makes it impossible to automatically complete the grabbing and releasing of the container.

[0094] In one embodiment, in semi-automatic control mode or local maintenance mode, central control personnel can perform corresponding control or maintenance operations through an operation console. The operation console can be divided into a general remote operation station (ROS) and a maintenance remote operation station (MROS).

[0095] Specifically, when a risk situation arises or a fault message is received, the automatic control mode can be switched to semi-automatic control mode. The remote operation control system (ROCS) then assigns tasks to the ROS based on the operating mode of the crane's automated control device, allowing the remote operator to complete the subsequent operations. If a general fault occurs during the crane's automatic operation, such as an abnormal signal jump or sensor malfunction, these general faults can be reset, pose no safety risks, and do not affect subsequent automatic operation. At this time, the ROCS assigns tasks to the MROS based on the current operating mode to enable the automatic operation to be handled through emergency measures. After the MROS remote operation is completed, the operator console task is released and the crane returns to automatic control mode.

[0096] When a serious fault occurs in a crane, such as the inability to execute automatic control tasks or hardware damage, the serious fault is generally reported by the basic electronic control device. At this time, maintenance personnel are required to enter the electrical room, turn on the local maintenance switch, and manually switch to local maintenance mode to hand over control of the crane to the staff.

[0097] In one embodiment, the crane's operating status and fault information can be recorded in real time for easy access by maintenance personnel. Specifically, the crane automation control device can communicate with a status log reporting system (SRSL). The status log reporting system records and manages the crane's operating status and fault information in real time, regularly generating report logs for easy access by maintenance personnel, and improving maintenance efficiency. Expired report logs can be periodically deleted after a certain period of storage.

[0098] In practice, crane control modes can be categorized as automatic and semi-automatic. In automatic control mode, the crane's automated control device responds to execution instructions, fully automatically completing corresponding control operations without requiring human intervention. In semi-automatic control mode, the crane's automated control device responds to execution instructions and semi-automatically performs corresponding control operations, with some manual intervention required. Each mode is described in detail below, using specific embodiments.

[0099] First, the automatic control mode is used as an example for explanation.

[0100] See also Figure 7 , Figure 7 This is a flow chart of the task of grabbing or placing boxes in the automatic control mode provided by this application. Correspondingly, the execution instruction is grabbing boxes in the yard or placing boxes in the yard.

[0101] S710: In response to the yard container grabbing instruction or the yard container releasing instruction, generate and send corresponding navigation control instructions to the basic electronic control device, so that the basic electronic control device controls the trolley mechanism and the small trolley mechanism of the crane to reach the specified position.

[0102] S720: Send a scan instruction to the TDS to trigger the TDS to scan the target object, and receive target detection information fed back by the TDS.

[0103] S730: Determine whether a TDS scan failure occurs.

[0104] S740: If a TDS scan failure occurs, the automatic control mode is switched to a semi-automatic mode to allow manual operation or switched to a local maintenance mode to facilitate maintenance by maintenance personnel.

[0105] S750: If no fault is found in the TDS scan, a lifting and lowering instruction is generated to control the lifting mechanism to descend to the target height.

[0106] Steps S720 to S750 are optional. In other embodiments, after the gantry and trolley mechanisms reach the designated positions, a lift / lower command may be generated to lower the lifting mechanism to the target height. It is understood that when the lifting mechanism is above the safe height, a spreader retraction command may be generated to retract the spreader to the target size, thereby facilitating subsequent container grabbing and placement.

[0107] S760: Generate a spreader fine-tuning instruction based on the spreader state information and the target detection information to control the spreader to align with the target object.

[0108] S770: Generate lifting and lowering instructions to control the lifting mechanism to continue to descend until the box lands.

[0109] When executing the stacking task, that is, when placing the container on the container, LCS can be used before S770 to confirm whether the container meets the alignment conditions. If the alignment conditions are met, the container placement operation is performed; if the alignment conditions are not met, a lifting instruction is generated to control the lifting mechanism to rise to a certain height, and then a spreader fine-tuning instruction is generated to correct the position of the spreader until the alignment conditions are met. Through the secondary container alignment, the accuracy of the stacking task is further guaranteed.

[0110] S780: Generate a spreader unlocking command or a spreader locking command based on the box landing signal or rope loosening signal fed back by the basic electronic control device to control the spreader to complete the box grabbing or releasing operation.

[0111] Understandably, the automated control process for automatically grabbing or placing containers on a container truck or AGV is similar and will not be explained here. In the automated control mode for grabbing or placing containers on a container truck or AGV, the container truck or AGV must first be guided to the target location before controlling the large and small vehicle mechanisms to reach the designated locations.

[0112] Next, the semi-automatic control mode is taken as an example for explanation.

[0113] See also Figure 8 , Figure 8 This is a flow chart of the task of grabbing or placing boxes in the semi-automatic control mode provided by this application. Correspondingly, the execution instructions are grabbing boxes in the yard or placing boxes in the yard.

[0114] S810: In response to a yard container grabbing instruction or a yard container releasing instruction, a corresponding navigation control instruction is generated and sent to a basic electronic control device, so that the basic electronic control device controls the trolley mechanism and the small trolley mechanism of the crane to reach a designated position.

[0115] S820: Send a scan command to the TDS to trigger the TDS to scan the target object, and receive target detection information fed back by the TDS.

[0116] S830: Determine whether a TDS scan failure occurs.

[0117] S840: If TDS scanning fails, jump directly to manual operation.

[0118] S850: If no fault is found in the TDS scan, a lifting and lowering instruction is generated to control the lifting mechanism to descend to the target height.

[0119] The above steps S820 to S850 are optional steps. In other embodiments, after the trolley mechanism and the small trolley mechanism reach the designated position, a lifting and lowering instruction may be directly generated to control the lifting mechanism to descend to the target height, which is not limited here.

[0120] S860: Jump to manual operation and manually control the box alignment, grabbing or placing operations.

[0121] S870: Manually control the lifting mechanism to rise to a safe height and switch to automatic control mode.

[0122] Understandably, the semi-automatic control process for grabbing or placing containers on a container truck or AGV is similar and will not be explained here in detail. In this semi-automatic control mode, the container truck or AGV must be guided to the target location before the large and small vehicle mechanisms are controlled to reach the target location.

[0123] This embodiment monitors crane risks and fault conditions in real time. Based on varying degrees of risk or fault, it adaptively switches to semi-automatic control mode or local maintenance mode to promptly resolve issues arising during automatic control, thereby improving the stability and safety of crane control. Furthermore, through fault detection and information exchange between various devices, accurate and timely fault detection is ensured. This, combined with flexible switching of control modes, further improves crane control efficiency.

[0124] In the several embodiments provided in this application, it should be understood that the disclosed methods and devices can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of modules or units is merely a logical functional division. In actual implementation, other division methods may be used. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not implemented.

[0125] It should be noted that the order in which the embodiments of the present invention are described above is for illustrative purposes only and does not represent the superiority or inferiority of the embodiments. The above description is of specific embodiments of this specification. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps described in the claims can be performed in an order different from that in the embodiments and still achieve the desired results. In addition, the processes depicted in the accompanying drawings do not necessarily require the specific order or sequential order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0126] The various embodiments in this specification are described in a progressive manner. Similar parts between the various embodiments can be referred to in conjunction with each other. Each embodiment focuses on the differences from other embodiments. In particular, the device embodiments are generally similar to the method embodiments, so the description is relatively simple. For relevant parts, refer to the description of the method embodiments.

[0127] Those skilled in the art will understand that all or part of the steps to implement the above embodiments may be accomplished by hardware, or by a program to instruct the relevant hardware, and the program may be stored in a computer-readable storage medium, which may be a read-only memory, a disk, or an optical disk, etc.

[0128] Units described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of these units may be selected to achieve the purpose of this embodiment according to actual needs.

[0129] In addition, each functional unit in each embodiment of the present application may be integrated into a processing unit, each unit may exist physically separately, or two or more units may be integrated into a single unit. The above-mentioned integrated units may be implemented in the form of hardware or software functional units.

[0130] The above description is merely an embodiment of the present application and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A crane automation control method, characterized in that: A crane automation control device used in a crane automation control system, wherein the crane automation control device stores multiple function control programs, including: Receive crane equipment type and execution instructions; A function control program corresponding to the device type and the execution instruction call is used as a control program; Running the control program to control the crane to perform the operation corresponding to the execution instruction; The functional control program is selected from one, two or more of a motion control program, an automatic box alignment program, and a truck deviation correction program; The crane automation control system further comprises a basic electric control device, wherein the basic electric control device is communicatively connected with the crane automation control device; When the control program is the motion control program, the step of running the control program to control the crane to perform the operation corresponding to the execution instruction includes: Obtain detection information and operation status information; Generate a corresponding control instruction based on the execution instruction, the detection information, and the operating status information, wherein the detection information is target detection information, and the execution instruction is to place or grab a box. The step of generating the corresponding control instruction based on the execution instruction, the detection information, and the operating status information includes: in response to the execution instruction, judging whether the crane has reached the target corresponding position based on the target detection information and the operating status information; if so, generating a lifting and lowering instruction, wherein the lifting and lowering instruction is used to instruct the lifting mechanism of the crane to lower; Calculating a current operating parameter value based on the detection information, the operating status information, and a given operating parameter; The control instruction and the current operating parameter value are sent to the basic electric control device, so that the basic electric control device controls at least one operating mechanism of the crane to operate according to the current operating parameter value in response to the control instruction. Before the step of sending the control instruction and the current operating parameter value to the basic electric control device, it includes: judging whether the height of the lifting mechanism of the crane is greater than the safety height; if so, executing the step of sending the control instruction and the current operating parameter value to the basic electric control device; if not, not executing the step of sending the control instruction and the current operating parameter value to the basic electric control device to avoid collision between equipment.

2. The crane automation control method according to claim 1, characterized in that: The execution instruction is to place the box or grab the box, and the equipment type is tire type. The function control program corresponding to the equipment type of the crane and the execution instruction call is a step of the control program, including: In response to the execution instruction, the motion control program, the automatic box alignment program and the trolley deviation correction program corresponding to the tire crane are called as the control program.

3. The crane automation control method according to claim 1, characterized in that: The equipment type is rail-type, When the execution instruction is to place a box, the step of calling the function control program corresponding to the execution instruction based on the equipment type of the crane as the control program includes: calling the motion control program and the automatic box matching program corresponding to the rail crane as the control program in response to the execution instruction, When the execution instruction is to grab a box, the step of calling the corresponding function control program based on the equipment type of the crane and the execution instruction as the control program includes: responding to the execution instruction, calling the motion control program corresponding to the rail crane as the control program.

4. The crane automation control method according to claim 1, characterized in that: The method further comprises: Based on the equipment type, given operating parameters of each operating mechanism in the crane are configured, where the given operating parameters include a maximum operating speed, a maximum operating acceleration, and a maximum operating distance.

5. The crane automation control method according to claim 1, characterized in that: The lifting mechanism of the crane is provided with a sling. When the control program is the automatic box alignment program, the step of running the control program to control the crane to perform the operation corresponding to the execution instruction includes: Obtain spreader status information and target detection information; Based on the spreader status information and the target detection information, a spreader fine-tuning instruction is generated, where the spreader fine-tuning instruction is used to instruct the spreader to align with the target object, thereby completing the box alignment operation.

6. The crane automation control method according to any one of claims 1 or 5, characterized in that: The control program includes a motion control program and an automatic box alignment program. After the operation control based on the operation control program is completed, the automatic box alignment program is run in response to the hoisting mechanism of the crane descending to the target height.

7. The crane automation control method according to claim 1, characterized in that: When another crane appears within the safety range of the crane, the method further includes: Obtaining the operating status information of the crane, given operating parameters, and operating information of adjacent cranes; Based on the operating status information, the given operating parameters and the operating information of the neighboring crane, the maximum safe speed of the crane is calculated and updated in real time, so that the operating speed of the crane is lower than the maximum safe speed to avoid collision between cranes.

8. The crane automation control method according to claim 1, characterized in that: The method further comprises: monitoring the crane to see if a risk situation occurs or if a fault message is received; If so, the automatic control mode is switched to the semi-automatic control mode to facilitate operator coordination, or switched to the local maintenance mode to facilitate maintenance by maintenance personnel.

9. The crane automation control method according to claim 8, characterized in that: The method further comprises: The operating status information and the fault information of the crane are recorded in real time for viewing by maintenance personnel.

10. A crane automation control system, characterized in that: It comprises a crane automation control device and a central control server that are communicatively connected to each other, the central control server is used to send execution instructions to the crane automation control device, and the crane automation control device is used to implement the crane automation control method according to any one of claims 1-9.

11. The crane automation control system according to claim 10, characterized in that: It also includes a basic electric control device, which is communicatively connected to the crane automation control device; the basic electric control device is used to receive control instructions sent by the crane automation control device and control the operation of at least one operating mechanism of the crane in response to the control instructions.

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