Operation control system and operation control method of intelligent gantry vehicle

Abstract

The application discloses an operation control system of an intelligentized gantry vehicle, adopts a three-stage control mode, namely, three control terminals are arranged from top to bottom, and are respectively a first-stage control terminal, a second-stage control terminal and a third-stage control terminal; the first-stage control terminal is a general control platform arranged in a general control room (1); the second-stage control terminal is an operation console (3) arranged in a production operation area; and the third-stage control terminal is a remote controller. The application further discloses an operation control method of the operation control system. By adopting the technical scheme, accurate positioning can be realized, the safety of the gantry vehicle is improved, the automation and intelligentization level of the operation control of the gantry vehicle is improved, and the production efficiency is further improved.

Description

An intelligent gantry crane operation control system and its operation control method Technical Field

[0001] This invention belongs to the technical field of construction equipment for building engineering. It relates to the field of intelligent upgrading technology for steel bar processing plants, specifically an intelligent gantry crane one-button call system and control method for multi-operation area positioning. Background Technology

[0002] Gantry cranes are one of the most commonly used lifting equipment in modern processing plants, with advantages such as simple structure and convenient operation. In steel bar processing plants in the construction industry, gantry cranes are usually the most important hoisting equipment, and they are responsible for all aspects of the logistics operation from raw steel bars to semi-finished steel bars.

[0003] The independent moving structural components of the gantry crane that are effective in operation include the crossbeam, the trolley, and the hook, which move in the forward-backward, left-right, and up-down directions, respectively.

[0004] Currently, the conventional gantry crane control method in steel bar processing plants is usually as follows: when a hoisting requirement occurs in a certain work area, the worker goes to the gantry crane remote control storage location to retrieve the remote control, first controls the gantry crane to move to the hoisting area for coarse positioning, then performs precise positioning of the gantry crane according to the hoisting point, and finally carries out the hoisting operation.

[0005] Therefore, when using the remote control to operate the gantry crane, workers need to operate at least three corresponding control buttons. Typically, workers hold the remote control with both hands and press the buttons simultaneously, but can only press a maximum of two control buttons at a time, resulting in at least one independent moving component of the gantry crane not being operational at the same time.

[0006] While the aforementioned traditional gantry crane control systems and methods are relatively flexible, they have the following limitations:

[0007] The number of remote controllers for gantry cranes is often determined by the number of gantry cranes. Each gantry crane has only one valid remote controller. Before each use, the remote controller needs to be retrieved from the storage point, and after use, it needs to be returned to the storage point, which consumes some of the workers' effective working time. However, this process is only an idealized control method. In actual production, it is common for workers to forget to return the remote controller after using the gantry crane, forcing the next user to search for the remote controller within the factory, further affecting the factory's processing efficiency.

[0008] In addition, existing gantry crane control systems generally do not have position sensors for each moving structural component. The scheduling and use of gantry cranes often rely on worker judgment, and the position information of gantry cranes cannot be obtained from a higher-level management interface. This makes it difficult to meet the current needs of industrialized steel bar processing for information feedback and intelligent scheduling of gantry crane equipment.

[0009] In conclusion, existing gantry crane control systems are no longer sufficient to meet the development needs of automated and intelligent steel bar processing. Summary of the Invention

[0010] This invention provides an intelligent gantry crane operation control system, the purpose of which is to improve the automation and intelligence level of gantry crane operation control, thereby improving production efficiency.

[0011] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0012] The present invention discloses an intelligent gantry crane operation control system. The gantry crane includes a crossbeam, a trolley, and a hook. The gantry crane runs on the gantry crane track via crossbeam drive mechanisms at both ends of the crossbeam. The operation control system adopts a three-level control method, that is, three control terminals are set from top to bottom, namely a primary control terminal, a secondary control terminal, and a tertiary control terminal. The primary control terminal is a central control platform set in the central control room; the secondary control terminal is an operation control console set in the production operation area; and the tertiary control terminal is a remote control.

[0013] When the upper-level control terminal controls the operation of the gantry crane, the lower-level control terminal is locked and cannot control the gantry crane.

[0014] Position sensors are respectively installed on the crossbeam, trolley, hook, and top.

[0015] The production operation area includes three types of operation areas: raw material area, equipment production area, and semi-finished product area; an operation control console is set up in each operation area.

[0016] The control console includes a fixed base plate, a column, and an operation panel; the operation panel is equipped with indicator lights, a power switch, and multiple operation control keys.

[0017] The operation control keys include two beam control keys, two trolley control keys, two hook control keys, one end key, one start key, and four positioning keys.

[0018] To achieve the same inventive objective as the aforementioned technical solutions, this invention also provides an operation control method for the intelligent gantry crane operation control system described above, characterized in that: the gantry crane operation control system is equipped with an intelligent scheduling system and a collision avoidance system; wherein:

[0019] The intelligent scheduling system, based on optimal response time, selects the gantry crane closest to the call point and establishes a control signal connection with the control console when one of the operation consoles makes a call connection, according to the position of each gantry crane.

[0020] The collision avoidance system determines whether a collision will occur by using the coordinates of each gantry crane. A safe distance is set between each gantry crane. When the distance between two gantry cranes shrinks to a safe threshold, the gantry cranes are forced to stop and an alarm is triggered to prevent collisions between the gantry cranes.

[0021] When hoisting operations are required in a certain work area, press the power button on the control console to power on the control console;

[0022] Press the start button. At this time, the intelligent dispatch system will start working and determine the gantry cranes connected to the operation console based on the distance between each gantry crane and the call point and whether it is in standby mode.

[0023] Observe the indicator light color: When the indicator light is green, it indicates that the control console has established a control signal connection with a certain gantry crane and the next operation can be performed; when the indicator light is red, it indicates that all gantry cranes are being used at other workstations and you need to wait until the indicator light turns green before you can perform the next operation.

[0024] Based on the location of the lifting point in the work area, select the nearest positioning key and press it. At this time, the operation control system will simultaneously adjust the position and attitude of the gantry crane according to the predetermined coordinates of the beam, trolley and hook at the fixed point until the required point is reached, thus completing the coarse positioning of the gantry crane.

[0025] Based on the location of the lifting points, the gantry crane is precisely controlled using the crossbeam control key, trolley control key, and hook control key to carry out the lifting operation;

[0026] After the hoisting operation is completed, press the end button to disconnect the control console from the gantry crane;

[0027] Press the power button to power off the control console.

[0028] During the call connection process, the intelligent scheduling system selects the gantry cranes based on their current operating status, location coordinates, and whether a collision is likely to occur, thereby enabling the control signal connection between the operation console and the gantry cranes.

[0029] This invention employs the aforementioned technical solution, installing multiple position sensors on the intelligent gantry crane for accurate positioning; achieving closed-loop control of the gantry crane's designated position via an operation console, saving workers time spent using remote controls; simultaneously controlling three moving structural components—the crossbeam, trolley, and hook—saving at least one-third of the scheduling time compared to traditional manual operation, thus improving gantry crane utilization efficiency; enabling the fastest response selection and collision avoidance for dual gantry cranes through an intelligent scheduling system, further enhancing gantry crane utilization efficiency and safety; and acquiring real-time working status data from multiple gantry cranes through a digital twin system, providing a basis for visualizing the gantry crane's digital model, centralized control, and big data analysis of subsequent work point usage frequency, achieving visibility, controllability, and scheduling of the gantry crane, improving the automation and intelligence level of gantry crane operation control, and ultimately increasing production efficiency. Attached Figure Description

[0030] The following is a brief explanation of the contents shown in the attached figure and the markings therein:

[0031] Figure 1 is an axonometric view of the steel bar processing plant's work area;

[0032] Figure 2 is a horizontal projection of the work area in the steel bar processing plant;

[0033] Figure 3 is a side view of the steel bar processing plant's work area;

[0034] Figure 4 is a schematic diagram of the operation control console circled in Figure 1;

[0035] Figure 5 is an enlarged structural schematic diagram of part A in Figure 4;

[0036] Figure 6 is a flowchart of the one-click call process of the present invention;

[0037] Figure 7 is a structural diagram of the intelligent gantry crane operation control system of the present invention;

[0038] Figure 8 shows a schematic diagram of the location of the front hoisting vehicle for one-click call;

[0039] Figure 9 shows the location of the gantry crane after the one-click call.

[0040] The diagram is marked as follows:

[0041] 1. Central control room; 2. Ground; 3. Operation control console; 4. Gantry crane; 5. Raw material area; 6. Equipment production area; 7. Semi-finished product area; 8. Call point; 9. Gantry crane track.

[0042] 301. Fixed base plate; 302. Column; 303. Operation panel; 303A. Indicator light; 303B. On / off switch; 303C. Crossbeam control key; 303D. Trolley control key; 303E. Hook control key; 303F. End key; 303G. Start key; 303H. Positioning key.

[0043] 401. Crossbeam; 402. Trolley; 403. Hook; Detailed Implementation

[0044] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, so as to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention.

[0045] As shown in Figures 1 to 5, the structure of this invention is an intelligent overhead crane operation control system. The technical solution of this invention mainly includes a central control room 1, a ground platform 2, an operation control console 3, and an overhead crane 4. "Operating crane" is an industry term for a type of overhead crane.

[0046] The gantry 4 includes a crossbeam 401, a trolley 402, and a hook 403; the gantry 4 runs on the gantry track 9 via the crossbeam drive mechanism at both ends of the crossbeam 401.

[0047] The aforementioned gantry crane 4 is located within the production area of ​​the steel reinforcement processing plant. The layout of the steel reinforcement processing plant's work area, omitting the roof structure, is shown in Figures 1-3.

[0048] The production operation area includes three types of operation areas. The ground 2 is divided into three major operation areas according to different functions: raw material area 5, equipment production area 6, and semi-finished product area 7. An operation control console 3 is set up in each operation area.

[0049] In this invention, a steel bar processing plant with a double-gantry crane is used as an example for illustration. In the scheme, up, down, left, and right represent the relevant directions and have no special meaning. Their purpose is only to help with the illustration.

[0050] Each work area is assigned an operation control console 3, while the gantry crane 4 is installed on the gantry crane track 9 in the processing plant.

[0051] Specifically as follows:

[0052] The main structure of the gantry crane 4 consists of independently moving structural components: a crossbeam 401, a trolley 402, and a hook 403; as shown in the diagram:

[0053] The crossbeam 401 moves along the X-axis, defined as the front and rear directions;

[0054] The trolley 402 moves along the Y-axis, defined as the left and right directions;

[0055] The hook 403 moves along the Z-axis, defined as the up and down directions.

[0056] To address the problems and shortcomings of existing technologies, and to improve the automation and intelligence level of gantry crane operation control, thereby increasing production efficiency, the technical solution adopted by this invention is as follows:

[0057] As shown in Figures 1 to 5, the intelligent gantry crane operation control system of the present invention adopts a three-level control method, that is, three control terminals are set from top to bottom, namely a primary control terminal, a secondary control terminal, and a tertiary control terminal; the primary control terminal is the central control platform set in the central control room 1; the secondary control terminal is the operation control console 3 set in the production operation area; and the tertiary control terminal is a remote controller.

[0058] This invention aims to solve the problems of low automation and intelligence levels and low scheduling efficiency of gantry cranes in the production operation area of ​​steel bar processing plants in the prior art. In view of the characteristics of traditional gantry cranes, it adds position detection sensors for beams, trolleys and hooks, adds hardware systems such as in-situ operation consoles and central control tablets, builds an intelligent gantry crane one-click call scheduling system based on multi-operation area positioning, and builds a gantry crane digital twin system based on real-time data driving, that is, the operation control of two gantry cranes with the same function.

[0059] Based on the functional layout of the steel bar processing plant area, a primary control platform—the central control tablet—is added, with the main control terminal at its core. Secondary control platforms—operation control consoles—are added at each workstation / workpoint. Intelligent scheduling and control algorithms enable the gantry crane to achieve one-button call functionality based on optimal response time and intelligent collision avoidance. Position sensor information from various moving structural components of the gantry crane is used to visualize the gantry crane within a digital twin system. Combined with a three-level remote control, a hierarchical control unit for the gantry crane is formed, enabling centralized control, fixed-point control, and free control of the gantry crane.

[0060] As shown in Figure 6:

[0061] When the upper-level control terminal controls the operation of the gantry crane 4, the lower-level control terminal is locked and cannot control the gantry crane 4.

[0062] In addition to the control console 3, the control terminal of the gantry crane 4 can also be controlled via the central control tablet and a traditional remote control;

[0063] The central control tablet has the highest control authority and is a first-level control terminal, used by the steel reinforcement processing plant management to perform overall scheduling of the gantry crane 4. When the central control tablet is in use, neither the operation console 3 nor the remote control can control the gantry crane 4.

[0064] The operation console 3 is a secondary control terminal used by staff in various functional areas to schedule the gantry crane 4. When the operation console 3 is in use, the remote control cannot control the gantry crane 4.

[0065] The remote control is a three-level control terminal. When the gantry crane 4 requires real-time manual control in certain usage scenarios, the remote control is used.

[0066] The main control room 1 is equipped with a digital twin platform for the gantry crane 4. The digital twin model is driven in real time through the feedback signals from the sensors on the gantry crane 4, so as to realize the digital visualization and supervision of the gantry crane 4.

[0067] Position sensors are respectively installed on the crossbeam 401, trolley 402, hook 403 and the top.

[0068] There are three types of work areas: raw material area 5, equipment production area 6, and semi-finished product area 7; each of these work areas is equipped with an operation control console 3.

[0069] The traditional gantry crane is upgraded by adding position sensors to the crossbeam 401, trolley 402 and hook 403. The position sensor data is fed back to the digital twin system in real time through the control system and gateway, so as to realize the real-time driving of the digital twin model.

[0070] Each moving part is equipped with a position sensor, which transmits the position coordinate information to the control system in real time via PLC, reflecting the current position and attitude of the gantry crane. It is also equipped with a gateway and wireless transmission accessories, enabling it to interact with the control terminal and information terminal.

[0071] The structure of the operation console 3 is shown in Figures 4 and 5:

[0072] The operation control console 3 includes a fixed base plate 301, a column 302, and an operation panel 303;

[0073] The fixed base plate 301 is connected to the ground 2, and the column 302 raises the operation panel 303 to an appropriate position according to the height of the person. The operation panel 303 integrates all function buttons of the one-button call system.

[0074] The operation panel 303 is equipped with an indicator light 303A, a power switch 303B, and multiple operation control keys.

[0075] in:

[0076] Indicator light 303A is used to indicate whether the operation control console 3 has established a communication connection with a certain gantry crane 4: when it is green, it indicates that a control communication connection has been established with a certain standby gantry crane 4; when it is red, it indicates that no control communication connection has been established with any gantry crane 4, and at the same time, it indicates that all gantry cranes are being used at other workstations.

[0077] The 303B switch is the power-on / power-off button on the control panel.

[0078] The operation control keys include two beam control keys 303C, two trolley control keys 303D, two hook control keys 303E, one end key 303F, one start key 303G, and four positioning keys 303H.

[0079] in:

[0080] Two crossbeam control keys 303C are used to control the forward and backward movement of crossbeam 401 respectively;

[0081] Two control buttons 303D are used to control the left and right movements of the 402 trolley, respectively.

[0082] Two hook control keys 303E are used to control the up and down movement of hook 403 respectively;

[0083] The end button 303F is used to indicate that the use of gantry crane 4 has ended and the control communication with the gantry crane 4 has been disconnected after the hoisting operation is completed.

[0084] The start button 303G is used to establish a control communication connection with the standby gantry crane 4 before using the gantry crane 4 for hoisting operations.

[0085] The four positioning keys 303H represent the four fixed points of the functional area. After setting the coarse positioning coordinates of the functional area in advance, pressing the corresponding button will cause the gantry crane 4 to move automatically to the point.

[0086] The usage of each button is shown in Figure 6.

[0087] The system structure and usage method of the gantry crane 4 in this invention are shown in Figure 7, and the specific analysis is as follows:

[0088] To achieve the same inventive objective as the aforementioned technical solutions, this invention also provides an operation control method for the intelligent gantry crane operation control system described above, characterized in that: the gantry crane operation control system is equipped with an intelligent scheduling system and a collision avoidance system; wherein:

[0089] The intelligent scheduling system, based on the optimal response time, selects the gantry crane 4 closest to the call point 8 and establishes a control signal connection with the operation console 3 when one of the operation consoles 3 makes a call connection, according to the position of each gantry crane 4.

[0090] The collision avoidance system determines whether a collision will occur by using the coordinates of each gantry crane 4. A safe distance is set between each gantry crane 4. When the distance between two gantry cranes 4 is reduced to a safe threshold, the gantry crane 4 is forced to stop and an alarm is triggered to prevent collisions between the gantry cranes 4.

[0091] The intelligent scheduling system of this invention integrates an intelligent scheduling algorithm based on optimal response time and a collision avoidance algorithm to improve the utilization efficiency of the gantry crane.

[0092] The control process is as follows (refer to Figure 6):

[0093] When hoisting operations are required in a certain work area, press the power switch 303B on the operation control console 3 to power on the operation control console 3;

[0094] Press the start button 303G. At this time, the intelligent dispatch system will work and determine the gantry 4 connected to the operation console 3 based on the distance between each gantry 4 and the call point 8 and whether it is in standby mode.

[0095] Observe the color of indicator light 303A: When indicator light 303A is green, it indicates that the operation control console 3 has established a control signal connection with a certain gantry crane 4 and the next operation can be performed; when indicator light 303A is red, it indicates that all gantry cranes 4 are being used at other workstations and you need to wait until indicator light 303A turns green before you can perform the next operation.

[0096] Based on the location of the lifting point in the work area, select the nearest positioning key 303H and press it. At this time, the operation control system adjusts the position and attitude of the gantry crane 4 simultaneously according to the predetermined coordinates of the beam 401, trolley 402 and hook 403 at the fixed point until it reaches the required position, thus completing the coarse positioning of the gantry crane 4.

[0097] Based on the lifting point position, the gantry crane 4 is precisely controlled through the crossbeam control key 303C, the trolley control key 303D, and the hook control key 303E to carry out the lifting operation;

[0098] After the hoisting operation is completed, press the end button 303F to disconnect the control console 3 from the gantry crane 4;

[0099] Press the power switch 303B to power off the operation control panel 3.

[0100] The before and after diagrams are shown in Figures 8 and 9.

[0101] During the call connection process, the intelligent scheduling system selects the gantry crane 4 based on the current operating status, position coordinates, and whether a collision will occur, thereby realizing the control signal connection between the operation console 3 and the gantry crane 4.

[0102] In summary, the intelligent gantry crane one-click call system and method based on multi-operation area positioning proposed in this invention aims to improve the efficiency of gantry crane utilization and further enhance the automation and intelligence level of steel bar processing plant facilities in the construction industry by upgrading and transforming traditional gantry cranes with intelligence, and adding multi-level control facilities, digital twin systems, and intelligent scheduling systems. Starting from the gantry crane hardware, software, and control system, and differing from the traditional gantry crane operation method, it has the following beneficial effects:

[0103] This invention employs an intelligent gantry crane equipped with a position sensor, which can achieve closed-loop control of the gantry crane's position at a specified point through an in-situ operation control console. This saves workers the time and effort of using a remote control and improves hoisting production efficiency.

[0104] The one-button call system can simultaneously control three moving structural components: the crossbeam, the trolley, and the hook. Compared with the traditional manual operation method, it saves at least one-third of the scheduling time and improves the efficiency of the gantry crane.

[0105] The intelligent scheduling system enables the fastest response selection and collision avoidance for the dual gantry cranes, improving the efficiency and safety of gantry crane usage;

[0106] The digital twin system enables real-time acquisition of gantry crane operating data, providing a basis for the visualization, centralized control, and big data analysis of the frequency of use of subsequent operation points of the gantry crane digital model, thus realizing the visibility, controllability, and scheduling of the gantry crane in operation.

[0107] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. An intelligent gantry crane operation control system, wherein the gantry crane (4) includes a crossbeam (401), a trolley (402), and a hook (403); the gantry crane (4) runs on the gantry crane track (9) via crossbeam drive mechanisms at both ends of the crossbeam (401); characterized in that: The operation control system adopts a three-level control method, that is, three control terminals are set from top to bottom, namely a primary control terminal, a secondary control terminal and a tertiary control terminal; the primary control terminal is the central control platform set in the central control room (1); the secondary control terminal is the operation control console (3) set in the production operation area; the tertiary control terminal is a remote control; when the upper-level control terminal controls the operation of the gantry crane (4), the lower-level control terminal is locked and cannot control the gantry crane (4); the production operation area includes three types of operation areas, namely the raw material area (5), the equipment production area (6) and the semi-finished product area (7); in each operation area An operation control console (3) is installed inside; the gantry crane operation control system is equipped with an intelligent scheduling system and a collision avoidance system; wherein: the intelligent scheduling system starts from the optimal response time, when one of the operation control consoles (3) makes a call connection, it selects the gantry crane (4) closest to the call point (8) according to the position of each gantry crane (4) and establishes a control signal connection with the operation control console (3); the collision avoidance system judges whether a collision will occur by the point coordinates of each gantry crane (4), sets a safe distance between each gantry crane (4), and when the distance between two gantry cranes (4) is reduced to the safe threshold, the gantry crane (4) is forced to stop and alarms are triggered to prevent collisions between gantry cranes (4).

2. The intelligent gantry crane operation control system according to claim 1, characterized in that: Position sensors are respectively installed on the crossbeam (401), trolley (402), hook (403) and the top.

3. The intelligent gantry crane operation control system according to claim 1, characterized in that: The operation control console (3) includes a fixed base plate (301), a column (302) and an operation panel (303); the operation panel (303) is provided with an indicator light (303A), a power switch (303B) and multiple operation control keys.

4. The intelligent gantry crane operation control system according to claim 3, characterized in that: The operation control keys include two beam control keys (303C), two trolley control keys (303D), two hook control keys (303E), one end key (303F), one start key (303G), and four positioning keys (303H).

5. The operation control method of the intelligent gantry crane operation control system according to any one of claims 1 to 4, characterized in that: When a hoisting operation is required in a certain work area, press the power switch (303B) on the control console (3) to power on the control console (3); press the start button (303G). At this time, the intelligent dispatch system will work and determine the hoisting machine (4) connected to the control console (3) based on the distance between each gantry crane (4) and the call point (8) and whether it is on standby; observe the color of the indicator light (303A): when the indicator light (303A) is green, it indicates that the control console (3) has generated a control signal connection with a certain gantry crane (4) and can proceed to the next step; when the indicator light (303A) is red, it indicates that all gantry cranes (4) are being used at other work stations and need to wait until the indicator light (303A) is green before proceeding. Next step: Based on the location of the lifting point in the work area, select the nearest positioning key (303H) and press it. At this time, the operation control system adjusts the position and attitude of the gantry crane (4) according to the predetermined coordinates of the fixed point, the crossbeam (401), the trolley (402), and the hook (403) until it reaches the required position, thus completing the coarse positioning of the gantry crane (4). Based on the location of the lifting point, the gantry crane (4) is precisely controlled by the crossbeam control key (303C), the trolley control key (303D), and the hook control key (303E) to carry out the lifting operation. After the lifting operation is completed, press the end key (303F) to disconnect the connection between the operation control console (3) and the gantry crane (4). Press the power switch (303B) to de-energize the operation control console (3).

6. The operation control method of the intelligent gantry crane operation control system according to claim 5, characterized in that: During the call connection process, the intelligent scheduling system selects the gantry cranes (4) based on the current working status, position coordinates and whether a collision will occur, thereby realizing the control signal connection between the operation console (3) and the gantry cranes (4).

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