A mounting control system for a chain hoist

Abstract

The application relates to the technical field of crane control systems, and discloses a mounting control system of a chain type crane, which comprises a background server, a mounting process module, a debugging control module and a monitoring module; the mounting process module is used for real-time monitoring and independently recording a mounting process and standard checking in a mounting process, and can analyze and judge the correctness of mounting operation in the background; the monitoring module is used for real-time monitoring of mechanical equipment parameter data of the crane through multiple groups of sensors in the mounting and debugging process; in the debugging control process, the debugging control module is used for acquiring real-time data information collected by the monitoring module in the debugging process, and comprehensively analyzing the stability coefficient and determining the load weight degree through parameters of the crane and mechanical linkage driving data. The system is used for troubleshooting safety hazards in the mounting and debugging process.

Description

Technical Field

[0001] This invention relates to the field of crane control system technology, specifically to an installation control system for a chain crane. Background Technology

[0002] The functions of a crane and a hoist are the same; a crane is included in lifting machinery, but a hoist has a broader scope. Elevators and lifts are lifting equipment, but they cannot be called cranes. A crane specifically refers to a machine that uses winches and pulleys to lift objects. A chain crane, on the other hand, uses a lifting chain and hook for lifting. Chain cranes are made of metal links, and compared to wire rope cranes, they experience less wear and are more corrosion-resistant, leading to their increasingly widespread use in various industries.

[0003] Chain cranes are now controlled by electrical control systems. However, some control wiring connections are messy, usually due to improper installation or neglect of crane equipment debugging and inspection. For example, problems such as brake failure or cracked or deformed hooks may occur even when the crane is not overloaded. Therefore, eliminating safety hazards in cranes is an issue that needs to be taken very seriously. Summary of the Invention

[0004] This invention provides an installation and control system for a chain crane. During installation and commissioning, it performs multi-method load testing and emergency adjustments, and uses sensor data monitored for environmental data, amplitude, and frequency to obtain a stability coefficient, thus improving the safety of subsequent construction. This addresses the problems mentioned in the background section, such as messy control wiring, which is generally caused by improper installation or neglect of crane equipment inspection and debugging. Examples include brake failure in cranes and cracked or deformed hooks even when the crane is not overloaded. Therefore, eliminating these safety hazards in cranes is a crucial issue that requires attention.

[0005] This invention provides the following technical solution: an installation control system for a chain crane, the system comprising a back-end server, an installation process module, a debugging control module, and a monitoring module; the back-end server, installation process module, debugging control module, and monitoring module are connected via WIFI, Bluetooth, or multiple communication ports;

[0006] The installation process module is used to monitor and independently record the installation process in real time and conduct standardized inspections during the installation process. It can also analyze and judge the correctness of the installation operations in the background. The monitoring module is used to monitor the mechanical equipment parameter data of the crane in real time through multiple sets of sensors during the installation and debugging process. During the debugging and control process, the debugging data is collected in real time and sent to the debugging and control module. The debugging and control module is used to acquire the real-time data information collected by the monitoring module during the debugging process, and to conduct comprehensive analysis through the crane parameters and mechanical linkage drive data to obtain the stability coefficient and determine the load weight level.

[0007] The stability coefficient is determined based on data including the vibration of the crane boom, the overturning moment of the crane, the lifting moment, and the load data. The main measurement is the amplitude and frequency of the crane boom. Strong vibration increases the inertia of the suspended object and makes it easy to become unbalanced. Therefore, the linkage test parameter data is used as a reference for the determination.

[0008] As an optional solution for the installation control system of the chain crane described in this invention, the monitoring module includes a parameter monitoring module and an environmental testing module. The parameter monitoring module is used to monitor the main winch drive system, auxiliary winch lifting drive system, luffing drive system, winch brake, and slewing drive system of the crane in real time through multiple sets of sensors.

[0009] The multiple sensor groups include a weight sensor, a vibration amplitude sensor, a pressure sensor, a tilt sensor, a rotation angle sensor, a height sensor, a temperature sensor, and an acceleration sensor;

[0010] The environmental testing module uses an anemometer and video surveillance to monitor the installation environment in real time.

[0011] As an optional solution for the installation control system of the chain crane described in this invention, the debugging control module includes an unloaded debugging unit and a load debugging unit.

[0012] The no-load debugging unit refers to testing the crane's luffing angle, slewing, main and auxiliary hook lifting and lowering time, and the linkage of various actions under no-load conditions.

[0013] The load testing unit refers to testing the crane's luffing angle, luffing, slewing, main and auxiliary hook lifting and lowering time, and the linkage of each action under different load conditions, selecting 30%, 50%, 80%, 100%, and 120% of the maximum safe load as measurement points.

[0014] During the lifting process at 30%, 50%, 80%, 100%, and 120% of the load, the monitoring module monitors and records the following data in real time: actual displayed load, maximum and minimum amplitude angle, required time, hydraulic system pressure and control pressure, main motor current and voltage, amplitude data, and lifting time.

[0015] Among them, 100% and 120% are close to overload. Due to the action of the crane's own torque limiter, the crane's luffing action and hook raising action will be cut off, and only luffing raising and hook lowering actions can be performed. The overload is released by pressing the torque meter's forced switch. After the test is completed, check whether the hydraulic components, base and main components of the slewing mechanism are normal.

[0016] As an optional solution for the installation control system of the chain crane described in this invention, the debugging control module further includes an emergency test unit. The emergency test unit is used to stop the crane from moving by manually cutting off the power in an emergency, ensuring that the crane does not lower the load.

[0017] As an optional solution for the installation control system of the chain crane described in this invention, the emergency test unit includes emergency release, emergency slewing, emergency luffing and emergency braking.

[0018] The emergency release is used for emergency handling of the hook. The emergency handling steps are as follows: first, open the normally closed ball valve and close the normally open ball valve; then open the normally closed ball valve at the oil outlet of the manual pump, operate the manual pump to supply oil and open the brake. When the manual pump feels strained, it proves that the pressure has been established. Slowly open the normally closed throttle valve to control the heavy object to descend continuously and steadily under the action of gravity.

[0019] Additionally, adjusting the throttle valve during the lowering process can change the descent speed of the load. Closing the throttle valve or opening the drain valve on the manual pump can stop the release action. After the test is completed, restore the oil circuit valves to their normal state.

[0020] The emergency luffing procedure involves first manually opening the pawl, and then following the same steps as the emergency release procedure. After debugging and testing, the oil circuit valves are restored to normal status.

[0021] The emergency slewing procedure is as follows: First, disconnect the slewing motor from the gearbox in the slewing drive; then open the normally closed ball valve and close the normally open ball valve; open the normally closed ball valve at the oil outlet of the manual pump, operate the manual pump to supply oil and open the brake; drive the slewing input shaft with a manual tool to make the crane slew in the required direction. During the slewing process, the slewing can be stopped by using the hand brake or opening the oil drain valve of the manual pump. After the test, restore the opening and closing of all pipelines and ball valves.

[0022] The emergency braking is performed using the brakes of the braking system and the downhill brake, or by cutting off the power.

[0023] As an optional solution for the installation control system of the chain crane described in this invention, the safe range of the amplitude frequency setting is between 0.05MM and 1.50MM, and the safe value of the torsional vibration and lifting vibration of the boom is within 9Hz. The superposition of the normal amplitude frequency range is within 0.05M-1.50M, which is considered a normal amplitude state.

[0024] The amplitude frequency is ≥1.50 mm, and the torsional vibration of the crane boom is >9 Hz, which is a risky amplitude state and requires emergency handling.

[0025] As an optional solution for the installation control system of the chain crane described in this invention, the back-end server includes a fault module and a maintenance module;

[0026] The fault module is used to record and intelligently diagnose potential fault risks during the debugging process, and send the recorded and diagnostic information to the maintenance module, which is used to track and dispatch maintenance records.

[0027] As an optional solution for the installation control system of the chain crane described in this invention, the background server further includes a report analysis module, which is used to display the assembled crane and the debugging content in the form of a report.

[0028] As an optional solution for the installation control system of the chain crane described in this invention, the installation process module includes ground exploration and surface exploration operations, which are used to ensure that the ground and surface are flat and free of obstacles during installation, so as to facilitate installation and debugging and clear the site.

[0029] As an optional solution for the installation and control system of the chain crane described in this invention, the back-end server further includes a remote module, which enables remote repair of the equipment.

[0030] The present invention has the following beneficial effects:

[0031] 1. The installation control system of this chain crane allows for real-time monitoring and independent recording of the installation process, as well as standardized inspection. The backend can analyze the correctness of the operation and provide reminders through the monitoring installation screen, reducing problems caused by improper installation in later use.

[0032] 2. This invention relates to an installation and control system for a chain crane. During installation and commissioning, multiple sets of sensors are used for various debugging methods, including no-load, multi-load weight debugging, and emergency testing. Real-time data collected by the monitoring module is analyzed and referenced to obtain a stability coefficient, thereby determining the load weight level. This can reduce safety accidents caused by crane imbalance due to excessive load. Furthermore, four emergency methods—emergency release, emergency slewing, emergency luffing, and emergency braking—can be debugged and confirmed to be normal. During the crane's operation, in the event of a safety accident, the reliability and safety of emergency operations are guaranteed.

[0033] 3. The installation and control system of this chain crane monitors all data during the commissioning process through a back-end server, and records, intelligently diagnoses, reports and analyzes, remotely repairs and maintains any fault risks that may arise. This improves the speed of troubleshooting and resolving potential problems during installation and commissioning, and reduces potential safety issues and defects that may occur during the later use of the crane. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the system flow of the present invention.

[0035] Figure 2 This is a schematic diagram of the emergency testing unit of the present invention.

[0036] Figure 3 This is a schematic diagram illustrating the comparison between the working radius of the crane and the maximum lifting weight in this invention. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention,

[0038] All other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this invention. Example 1

[0039] Chain cranes are now controlled by electrical control systems. However, some control wiring connections are messy, usually due to improper installation or neglect of crane equipment debugging and inspection. For example, problems such as brake failure or cracked or deformed hooks may occur even when the crane is not overloaded. Therefore, eliminating safety hazards in cranes is an issue that needs to be taken very seriously.

[0040] This invention provides the following technical solution: an installation control system for a chain crane, the system comprising a back-end server, an installation process module, a debugging control module, and a monitoring module; the back-end server, installation process module, debugging control module, and monitoring module are connected via WIFI, Bluetooth, or multiple communication ports;

[0041] The installation process module is used to monitor and independently record the installation process in real time and conduct standardized inspections during the installation process. It can also analyze and judge the correctness of the installation operations in the background. The monitoring module is used to monitor the mechanical equipment parameter data of the crane in real time through multiple sets of sensors during the installation and debugging process. During the debugging and control process, the debugging data is collected in real time and sent to the debugging and control module. The debugging and control module is used to acquire the real-time data information collected by the monitoring module during the debugging process, and to conduct comprehensive analysis through the crane parameters and mechanical linkage drive data to obtain the stability coefficient and determine the load weight level.

[0042] The stability coefficient is determined based on data including the vibration of the crane boom, the overturning moment of the crane, the lifting moment, and the load data. The main measurement is the amplitude and frequency of the crane boom. Strong vibration increases the inertia of the suspended object and makes it easy to become unbalanced. Therefore, the linkage test parameter data is used as a reference for the determination.

[0043] In this embodiment: the installation process module monitors and independently records the installation process in real time and conducts standardized checks during the installation process. After the staff strictly follows the installation specifications at each step of the installation, experts check whether it meets the installation specifications. The background can analyze the correctness of the operation and provide reminders based on the real-time monitoring of the installation screen, reducing the possibility of short circuits caused by messy wiring due to non-standard installation.

[0044] During installation, multiple sets of sensors are installed in the drive electrical system of the chain crane. During the commissioning of the crane, the commissioning data is collected in real time and comprehensively analyzed through the crane parameters and mechanical linkage drive data to obtain the stability coefficient and determine the load weight. Based on the stability coefficient, potential safety hazards are eliminated, thereby improving the quality and efficiency of safe construction. Example 2

[0045] This embodiment is an explanation based on the previous embodiment. For details, please refer to [link / reference]. Figure 1 - Figure 3 The monitoring module includes a parameter monitoring module and an environmental testing module. The parameter monitoring module is used to monitor the main winch drive system, auxiliary winch lifting drive system, luffing drive system, winch brake, and slewing drive system of the crane in real time using multiple sets of sensors.

[0046] The multiple sensor groups include a weight sensor, a vibration amplitude sensor, a pressure sensor, a tilt sensor, a rotation angle sensor, a height sensor, a temperature sensor, and an acceleration sensor;

[0047] The environmental testing module uses an anemometer and video surveillance to monitor the installation environment in real time.

[0048] The debugging control module includes an unloaded debugging unit and a load debugging unit.

[0049] The no-load debugging unit refers to testing the crane's luffing angle, slewing, main and auxiliary hook lifting and lowering time, and the linkage of various actions under no-load conditions.

[0050] The load testing unit refers to testing the crane's luffing angle, luffing, slewing, main and auxiliary hook lifting and lowering time, and the linkage of each action under different load conditions, selecting 30%, 50%, 80%, 100%, and 120% of the maximum safe load as measurement points.

[0051] During the lifting process at 30%, 50%, 80%, 100%, and 120% of the load, the monitoring module monitors and records the following data in real time: actual displayed load, maximum and minimum amplitude angle, required time, hydraulic system pressure and control pressure, main motor current and voltage, amplitude data, and lifting time.

[0052] Among them, 100% and 120% are close to overload. Due to the action of the crane's own torque limiter, the crane's luffing action and hook raising action will be cut off, and only luffing raising and hook lowering actions can be performed. The overload is released by pressing the torque meter's forced switch. After the test is completed, check whether the hydraulic components, base and main components of the slewing mechanism are normal.

[0053] Lifting chains are mainly used in lifting machinery to lift heavy objects, with a working speed v≤0.25m / s. Traction chains are mainly used in chain conveyors to move heavy objects, with a working speed v≤4m / s.

[0054] Wherein: the safe range of the amplitude frequency setting is between 0.05MM and 1.50MM, the safe value of the torsional vibration and lifting vibration of the crane boom is within 9Hz, and the superposition of the normal amplitude frequency range is within 0.05M-1.50M, which is considered a normal amplitude state;

[0055] The amplitude frequency is ≥1.50 mm, and the torsional vibration of the crane boom is >9 Hz, which is a risky amplitude state and requires emergency handling.

[0056] Please refer to Figure 3 In, note:

[0057] 1. Working radius and working range refer to the horizontal distance between the crane's slewing center and the hook center;

[0058] 2. The maximum lifting capacity in this table refers to the maximum lifting limit under various working radius conditions;

[0059] In this embodiment, the main focus is on testing the crane under load. In the case of windy conditions in the construction environment, the load is adjusted. The stability coefficient is determined based on the vibration data of the boom, the overturning moment of the crane, the lifting moment, and the load data. The main method is to measure the amplitude and frequency of the boom to refer to the specific load values ​​for different crane specifications. Example 3

[0060] This embodiment is an explanation based on the previous embodiment. For details, please refer to [link / reference]. Figure 1 - Figure 3 The debugging control module further includes an emergency test unit, which is used to stop the crane from moving by manually cutting off the power in an emergency, ensuring that the crane does not lower the load.

[0061] The emergency testing unit includes emergency release, emergency turn, emergency luffing, and emergency braking.

[0062] The emergency release is used for emergency handling of the hook. The emergency handling steps are as follows: first, open the normally closed ball valve and close the normally open ball valve; then open the normally closed ball valve at the oil outlet of the manual pump, operate the manual pump to supply oil and open the brake. When the manual pump feels strained, it proves that the pressure has been established. Slowly open the normally closed throttle valve to control the heavy object to descend continuously and steadily under the action of gravity.

[0063] Additionally, adjusting the throttle valve during the lowering process can change the descent speed of the load. Closing the throttle valve or opening the drain valve on the manual pump can stop the release action. After the test is completed, restore the oil circuit valves to their normal state.

[0064] The emergency luffing procedure involves first manually opening the pawl, and then following the same steps as the emergency release procedure. After debugging and testing, the oil circuit valves are restored to normal status.

[0065] The emergency slewing procedure is as follows: First, disconnect the slewing motor from the gearbox in the slewing drive; then open the normally closed ball valve and close the normally open ball valve; open the normally closed ball valve at the oil outlet of the manual pump, operate the manual pump to supply oil and open the brake; drive the slewing input shaft with a manual tool to make the crane slew in the required direction. During the slewing process, the slewing can be stopped by using the hand brake or opening the oil drain valve of the manual pump. After the test, restore the opening and closing of all pipelines and ball valves.

[0066] The emergency braking is performed using the brakes of the braking system and the downhill brake, or by cutting off the power.

[0067] In this embodiment, by debugging four emergency methods—emergency release, emergency slewing, emergency luffing, and emergency braking—the normal release, slewing, luffing, and braking of the equipment are confirmed. This ensures the reliability and safety of emergency operations even in the event of a safety accident during the crane's deployment for construction. Example 4

[0068] This embodiment is an explanation based on the previous embodiment. For details, please refer to [link / reference]. Figure 1 - Figure 3 The backend server includes a fault module and a maintenance module.

[0069] The fault module is used to record and intelligently diagnose potential fault risks during the debugging process, and send the recorded and diagnostic information to the maintenance module, which is used to track and dispatch maintenance records.

[0070] The backend server also includes a report analysis module, which is used to display the assembled crane and the debugging content in the form of a report.

[0071] The installation process module includes above-ground exploration and ground exploration operations, which are used to ensure that the ground and ground are flat and free of obstacles during installation, so as to facilitate installation and debugging and clear the site.

[0072] The backend server also includes a remote module, which enables remote repair of the device.

[0073] In this embodiment, the backend server monitors all data during the debugging process and records, intelligently diagnoses, reports and analyzes, remotely repairs and maintains systems that generate potential fault risks. This improves the control during installation and debugging, quickly resolves and eliminates potential problems, and reduces safety issues caused by defects during the later use of the crane.

[0074] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0075] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. An installation control system for a chain crane, characterized in that: The system includes a backend server, an installation process module, a debugging control module, and a monitoring module; the backend server, installation process module, debugging control module, and monitoring module communicate with each other via WIFI, Bluetooth, or multiple communication ports. The installation process module is used to monitor and independently record the installation process in real time and conduct standardized inspections during the installation process. It can also analyze and judge the correctness of the installation operation in the background. The monitoring module is used to monitor the mechanical equipment parameter data of the crane in real time through multiple sets of sensors during the installation and debugging process. During the debugging and control process, the debugging data is collected in real time and sent to the debugging and control module. The debugging control module is used to acquire real-time data information collected by the monitoring module during the debugging process, and to conduct comprehensive analysis through the parameters of the crane and the mechanical linkage drive data to obtain the stability coefficient and determine the load weight level. The stability coefficient is determined based on data including the vibration of the crane boom, the overturning moment of the crane, the lifting moment, and the load data. The main measurement is the amplitude and frequency of the crane boom. Strong vibration increases the inertia of the suspended object and makes it easy to become unbalanced. Therefore, the linkage test parameter data is used as a reference for the determination.

2. The installation control system for a chain crane according to claim 1, characterized in that: The monitoring module includes a parameter monitoring module and an environmental testing module. The parameter monitoring module is used to monitor the main winch drive system, auxiliary winch lifting drive system, luffing drive system, winch brake, and slewing drive system of the crane in real time using multiple sets of sensors. The multiple sensor groups include a weight sensor, a vibration amplitude sensor, a pressure sensor, a tilt sensor, a rotation angle sensor, a height sensor, a temperature sensor, and an acceleration sensor; The environmental testing module uses an anemometer and video surveillance to monitor the installation environment in real time.

3. The installation control system for a chain crane according to claim 1, characterized in that: The debugging control module includes an unloaded debugging unit and a load debugging unit; The no-load debugging unit refers to testing the crane's luffing angle, slewing, main and auxiliary hook lifting and lowering time, and the linkage of various actions under no-load conditions. The load testing unit refers to testing the crane's luffing angle, luffing, slewing, main and auxiliary hook lifting and lowering time, and the linkage of each action under different load conditions, selecting 30%, 50%, 80%, 100%, and 120% of the maximum safe load as measurement points. During the lifting process at 30%, 50%, 80%, 100%, and 120% of the load, the monitoring module monitors and records the following data in real time: actual displayed load, maximum and minimum amplitude angle, required time, hydraulic system pressure and control pressure, main motor current and voltage, amplitude data, and lifting time. Among them, 100% and 120% are close to overload. Due to the action of the crane's own torque limiter, the crane's luffing action and hook raising action will be cut off, and only luffing raising and hook lowering actions can be performed. The overload is released by pressing the torque meter's forced switch. After the test is completed, check whether the hydraulic components, base and main components of the slewing mechanism are normal.

4. The installation control system for a chain crane according to claim 1, characterized in that: The debugging control module also includes an emergency test unit, which is used to stop the crane from moving by manually cutting off the power in an emergency, ensuring that the crane does not lower the load.

5. The installation control system for a chain crane according to claim 4, characterized in that: The emergency testing unit includes emergency release, emergency turn, emergency luffing, and emergency braking. The emergency release is used for emergency handling of the hook. The emergency handling steps are as follows: first, open the normally closed ball valve and close the normally open ball valve; then open the normally closed ball valve at the oil outlet of the manual pump, operate the manual pump to supply oil and open the brake. When the manual pump feels strained, it proves that the pressure has been established. Slowly open the normally closed throttle valve to control the heavy object to descend continuously and steadily under the action of gravity. Additionally, adjusting the throttle valve during the lowering process can change the descent speed of the load. Closing the throttle valve or opening the drain valve on the manual pump can stop the release action. After the test is completed, restore the oil circuit valves to their normal state. The emergency luffing procedure involves first manually opening the pawl, and then following the same steps as the emergency release procedure. After debugging and testing, the oil circuit valves are restored to normal. The emergency slewing procedure is as follows: First, disconnect the slewing motor from the gearbox in the slewing drive; then open the normally closed ball valve and close the normally open ball valve; open the normally closed ball valve at the oil outlet of the manual pump, operate the manual pump to supply oil and open the brake; drive the slewing input shaft with a manual tool to make the crane slew in the required direction. During the slewing process, the slewing can be stopped by using the hand brake or opening the oil drain valve of the manual pump. After the test, restore the opening and closing of all pipelines and ball valves. The emergency braking is performed using the brakes of the braking system and the downhill brake, or by cutting off the power.

6. The installation control system for a chain crane according to claim 1, characterized in that: The safe range for the amplitude frequency setting is between 0.05MM and 1.50MM. The safe value for the torsional vibration and lifting vibration of the crane boom is within 9Hz. The superposition of the normal amplitude frequency range is within 0.05M-1.50M, which is considered a normal amplitude state. The amplitude frequency is ≥1.50 mm, and the torsional vibration of the crane boom is >9 Hz, which is a risky amplitude state and requires emergency handling.

7. The installation control system for a chain crane according to claim 1, characterized in that: The backend server includes a fault module and a maintenance module; The fault module is used to record and intelligently diagnose potential fault risks during the debugging process, and send the recorded and diagnostic information to the maintenance module, which is used to track and dispatch maintenance records.

8. The installation control system for a chain crane according to claim 1, characterized in that: The backend server also includes a report analysis module, which is used to display the assembled crane and the debugging content in the form of a report.

9. The installation control system for a chain crane according to claim 1, characterized in that: The installation process module includes above-ground exploration and ground exploration operations, which are used to ensure that the ground and ground are flat and free of obstacles during installation, so as to facilitate installation and debugging and clear the site.

10. The installation control system for a chain crane according to claim 1, characterized in that: The backend server also includes a remote module, which enables remote repair of the device.

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