A gantry crane with self-repairing function and fault detection and repair method

Abstract

This invention discloses a gantry crane with self-healing function and a fault detection and repair method. The gantry crane includes two symmetrically arranged support mechanisms, a crossbeam mounted on the two support mechanisms, and a lifting device slidably mounted on the crossbeam via a positioning trolley. The support mechanisms are mounted on a traveling trolley. It also includes a crossbeam bending detection device mounted on the positioning trolley, a wheel fault detection device mounted on the wheels of the traveling trolley, a crossbeam reinforcement device, a wheelset replacement device, and a control system. This invention uses the crossbeam bending detection device and the wheel fault detection device to monitor the bending condition of the gantry crane's crossbeam and the working status of the wheels in real time, enabling timely detection of potential faults. When crossbeam bending is detected, the crossbeam reinforcement device automatically positions and reinforces the crossbeam. When a wheel fault occurs, the wheelset replacement device removes the damaged wheelset and installs a spare wheelset.

Description

Technical Field

[0001] This invention belongs to the field of crane technology, and relates to a gantry crane, and more particularly to a gantry crane with self-repair function. Background Technology

[0002] Gantry cranes are common construction machinery widely used for lifting and transporting large objects such as equipment and goods, both indoors and outdoors. When a gantry crane is working, its wheels control its forward and backward movement, while a trolley on the beam moves the load laterally. The wheels are the driving components for the crane's forward and backward movement, and also the components that bear the weight of the entire crane and the lifted goods. During use, damage may occur due to prolonged load, impact from foreign objects, or drive unit malfunctions, rendering the crane unable to move. Disassembling and replacing damaged wheelsets can be time-consuming. Furthermore, the crane's crossbeam is subjected to downward loads from the lifted goods, and this load is relatively concentrated, causing the crossbeam to bear significant bending moments. This can lead to hidden cracks, which, if not detected and addressed promptly, could result in a safety accident.

[0003] Patent application CN202122105833.2 discloses a gantry crane anti-collision self-stop device, which includes a detector located at the end of the gantry crane away from the crane body for identifying and detecting the surrounding environment, and a relay installed in the gantry crane control box. The relay is electrically connected to a signal transmission line, the end of which is electrically connected to the detector. This gantry crane anti-collision self-stop device uses ultrasonic or infrared detection to prevent collisions between the gantry crane body and personnel or other objects during operation. However, the above technology only reaches the data monitoring stage, collecting only the gantry crane's operating data. It cannot autonomously respond to malfunctions or damage, requiring manual intervention and maintenance, which consumes more time and manpower. Summary of the Invention

[0004] The purpose of this invention is to address the problems existing in the prior art by providing a gantry crane with self-repair function, which can automatically detect and eliminate wheel failures, crossbeam failures, etc., solve the problems of abnormal operation caused by wheel damage and crossbeam cracks, which prevent the gantry crane from working properly, and the time-consuming process of disassembling and replacing wheels. It can also avoid safety accidents caused by crossbeam cracks.

[0005] To achieve the above objectives, the present invention employs the following technical solutions.

[0006] The gantry crane with self-healing function provided by the present invention includes two symmetrically arranged support mechanisms, a crossbeam mounted on the two support mechanisms, and a lifting device slidably mounted on the crossbeam via a positioning trolley. The support mechanisms are mounted on a traveling trolley. The traveling trolley includes a base and first wheel sets mounted at both ends of the base. The gantry crane also includes:

[0007] A beam bending detection device is installed on a positioning trolley to detect the degree of bending of the beam at the position of the positioning trolley on the beam.

[0008] A wheel fault detection device is installed on the wheels of a traveling trolley to detect wheel speed and / or wheel drive motor current.

[0009] A beam reinforcement device includes a reinforcement slider and a drive unit that slides the reinforcement slider inside the beam, used to reinforce and bear load at the bending position of the beam;

[0010] A wheelset changing device, installed on a traveling trolley, is used to realize online replacement of the wheelsets of the traveling trolley. It includes a second wheelset assembly, a conveying assembly for conveying the second wheelset assembly, and a connecting assembly for fixing the first wheelset assembly or the second wheelset assembly to the base.

[0011] The control system is connected to the beam bending detection device, the wheel fault detection device, the beam reinforcement device, and the wheelset replacement device, respectively. It is used to evaluate the beam or wheel faults based on the detection results of the beam bending detection device or the wheel fault detection device, and control the beam reinforcement device or the wheelset replacement device to operate based on the evaluation results.

[0012] The aforementioned gantry crane with self-healing function includes a beam bending detection device primarily composed of several capacitive sensors, with the signal output terminals of these sensors connected to the control system. The beam bending detection device also includes a distance sensor mounted on a positioning trolley for measuring the distance between the trolley and any end of the beam. In a preferred embodiment, distance sensors are installed on both sides of the positioning trolley for positioning the trolley.

[0013] The aforementioned gantry crane with self-repair function includes a wheel fault detection device comprising a speed sensor and / or a current detector. The speed sensor is mounted on the wheel to detect the wheel speed; the current detector (e.g., a current clamp meter or a dynamic current sensor) is connected to the wheel drive motor to detect the wheel drive motor current.

[0014] The aforementioned gantry crane with self-healing function includes a drive unit in the beam reinforcement device comprising winches installed at both ends of the beam and ropes wound around the winches. One end of the rope is fixedly connected to one side of the reinforcement slider. At least one of the two winches is connected to a first drive motor, which drives the winches to rotate, thereby moving the reinforcement slider along the length of the beam. The reinforcement slider has a groove along its length. The beam is hollow inside and divided into two parts by a partition along its length. The lower part has a groove along its length to facilitate the movement of the positioning trolley, and the upper part is used to accommodate the beam reinforcement device. The partition protrudes upward, forming a track adapted to the groove of the reinforcement slider. Two rows of limiting grooves are formed on the contact surface between the inner side of the beam and the reinforcement slider. Several wedge-shaped blocks with the same structure are set in the limiting grooves, and the wedge-shaped blocks in the two rows of limiting grooves are inclined in opposite directions. The reinforcement slider and the beam are locked together by a pin assembly set in the cavity of the reinforcement slider. The pin assembly includes a support plate and pins mounted on the support plate. The support plate is mounted in the reinforced slider cavity via a lead screw, which drives the support plate to move up and down. The support plate is fixedly connected to a nut mounted on the lead screw. The lead screw is driven by a second drive motor, which rotates the lead screw, thereby moving the support plate up and down. There are two pins, each with its end face adapted to a wedge-shaped block in one of the two rows of slots on the crossbeam. Each pin includes a mounting base and a locking tongue disposed within the mounting base. One end of the locking tongue is connected to the bottom of the mounting base via a spring, and the other end extends out of the mounting base and adapts to the wedge-shaped block in one of the two rows of slots on the crossbeam.

[0015] The aforementioned gantry crane with self-healing function has the same structure for the first and second wheel assembly, including a housing and symmetrically arranged wheels mounted on the bottom of the housing. The conveying assembly includes a transverse conveyor belt along the length of the base and a vertical conveyor belt along the vertical direction; the transverse conveyor belt transports the second wheel assembly to the base wheel assembly mounting slot, and the vertical conveyor belt transports the first wheel assembly to the top of the base or the second wheel assembly to the base wheel assembly mounting slot. A photoelectric sensor is installed at the end of the transverse conveyor belt. A vertical conveyor belt is installed on each of the two opposite sides of the wheel assembly mounting slots at both ends of the base; the transverse and vertical conveyor belts are driven by a third drive motor and a fourth drive motor connected to them, respectively. The connecting assembly includes hydraulic fixing pins, hydraulic support rods, support frames, and telescopic electrical connectors symmetrically installed on both sides of the base. The pin heads of the hydraulic fixing pins pass through the base and insert into grooves on the surface of the second wheelset assembly housing. The hydraulic support rods support the base on the ground. The support frame lifts the first wheelset assembly delivered to the top of the base. The support frame rotates via a hinge assembly, which includes a connecting rod hinged to the side wall of the base and a fifth drive motor driven by the connecting rod. The telescopic electrical connector passes through the base and connects to the wheel drive motor and wheel fault detection device of the first or second wheelset assembly. The telescopic electrical connector is connected to the control system via a transmission line.

[0016] The control system can be a PLC controller or a computer server, electrically connected to the aforementioned beam bending detection device, wheel fault detection device, beam reinforcement device, and wheelset replacement device. Specifically, the control system is electrically connected to the beam bending detection device to acquire information from capacitive and distance sensors for detecting the degree of beam bending and simultaneously positioning the positioning trolley. The control system is also electrically connected to the wheel fault detection device to acquire information from speed and current sensors for detecting wheel operation. Furthermore, the control system is electrically connected to the beam reinforcement device to control the operation of the first and second drive motors, thereby moving the reinforcement slider to the reinforcement position and locking the slider. Finally, the control system is electrically connected to the wheelset replacement device to control the transmission assembly for transmitting the second wheelset assembly; simultaneously, it controls the hydraulic fixing pins, hydraulic support rods, and telescopic electrical joints of the connecting assembly to remove the first wheelset assembly and install and connect the second wheelset assembly. The control system operates in two modes: a manned mode and an unattended mode. In the manned mode, if a crossbeam or wheel malfunctions, the operator will activate the crossbeam reinforcement device or the wheelset replacement device. In the unattended mode, if a crossbeam or wheel malfunctions, the control system will automatically activate the crossbeam reinforcement device or the wheelset replacement device.

[0017] This invention also provides a method for fault detection and repair of gantry cranes, comprising the following steps:

[0018] The S1 beam bending detection device and wheel fault detection device send the detection data to the control system in real time.

[0019] Based on the received detection data, the S2 control system judges the degree of bending of the crossbeam and the operation of the wheels. If there is a fault in the crossbeam or the wheels, it proceeds to step S3; otherwise, it saves the detection data in real time and returns to step S1.

[0020] S3 determines whether the control system is in unattended mode. If yes, proceed to step S6; otherwise, proceed to step S4.

[0021] The S4 control system alerts the operator that there is a fault in the crossbeam or / and wheels. The operator confirms the fault. If the fault is confirmed, proceed to step S5; otherwise, return to step S1.

[0022] S5 is the operator stopping the gantry crane and proceeding to step S6;

[0023] S6 initiates the repair process; the repair process includes a beam reinforcement process and / or a wheelset component replacement process.

[0024] The S7 repair process is complete. The gantry crane is restarted and the process returns to step S1.

[0025] In step S1 above, the beam bending detection device detects the bending of the beam, mainly by collecting capacitance data through several capacitive sensors and sending it to the control system. The beam bending detection device also sends data from the distance measuring sensor mounted on the positioning trolley to the control system. The wheel fault detection device detects wheel operation, mainly by detecting wheel speed through a speed sensor and / or by detecting the drive motor current through a current detector, and sends the detection data to the control system.

[0026] In step S2 above, the control system judges the degree of bending of the crossbeam and the operation of the wheels based on the received detection data. For example, based on the capacitance data collected by several capacitance sensors, the system can determine the degree of bending of the crossbeam at its current position. If the degree of bending exceeds a set threshold, it determines that the crossbeam at the current position is faulty. The current position of the crossbeam can be determined by the control system through measurement data from a distance sensor. The control system can also determine whether the wheels are faulty based on the wheel speed or the detected drive current data. If the wheel speed exceeds the set range, stops, or changes abruptly, or if the detected change in drive motor current exceeds the set range, or if the drive motor current changes abnormally large or is open-circuited, it determines that the wheels are faulty.

[0027] In step S5 above, the operator stops the lifting equipment, positioning trolley and traveling trolley by controlling the system, thereby stopping the gantry crane.

[0028] In step S6 above, the beam reinforcement process is as follows: the control system first controls the first drive motor, which then drives the reinforcement slider to the location where the beam malfunctions. Then, it controls the second drive motor to lock the reinforcement slider to the beam.

[0029] The wheel assembly replacement process is as follows: The control system lowers the hydraulic support rod to the ground to support the base, then retracts the telescopic electrical connector to disconnect the electrical connection; next, the hydraulic fixing pin retracts, releasing the first wheel assembly from its fixation; the vertical conveyor belt is activated to move the first wheel assembly upwards to the top, and the support frame lifts the first wheel assembly for removal; the second wheel assembly is conveyed by the horizontal conveyor belt to the mounting slot of the base wheel assembly to be replaced, then by the vertical conveyor belt to the installation position; the hydraulic fixing pin is then used to fix the second wheel assembly to the base; the telescopic electrical connector is then connected to the second wheel assembly; finally, the hydraulic support rod is raised and retracted.

[0030] In step S7 above, the hoisting equipment and traveling trolley are restarted, thereby starting the gantry crane to work.

[0031] Compared with the prior art, the gantry crane with self-healing function provided by the present invention has the following beneficial effects:

[0032] (1) The present invention monitors the bending condition of the gantry crane beam and the working status of the wheels in real time through the beam bending detection device and the wheel fault detection device. It can detect the occurrence of fault risks in time, take preventive measures, suspend work, and at the same time remind the operators to improve the safety of equipment operation.

[0033] (2) When the beam is found to be bent, the present invention can automatically locate the abnormal bending position of the beam through the beam reinforcement device and reinforce the part in time to prevent the main beam from causing a larger crack and resulting in a safety accident.

[0034] (3) When a wheel failure occurs, the present invention can automatically remove the damaged wheelset and install the spare wheelset through the wheelset replacement device, thereby improving replacement efficiency and reducing workload. Attached Figure Description

[0035] Figure 1 This is a front view of a gantry crane with self-healing function provided in Embodiment 1 of the present invention;

[0036] Figure 2This is a side view of a gantry crane with self-healing function provided in Embodiment 1 of the present invention; wherein, (a) is a right view and (b) is a cross-sectional view along line AA in (a);

[0037] Figure 3 A schematic diagram of the assembly of the traveling trolley and the hoisting equipment;

[0038] Figure 4 This is a schematic diagram of the beam structure;

[0039] Figure 5 This is a schematic diagram of the cross-section of the beam;

[0040] Figure 6 This is a schematic diagram of a reinforced slider structure; where (a) is a perspective view, (b) is the front view, and (c) is a sectional view along line BB in (b).

[0041] Figure 7 A 3D schematic diagram of a gantry crane with self-healing capabilities;

[0042] Figure 8 for Figure 7 Enlarged diagram of section C;

[0043] Figure 9 This is a schematic diagram of the component structure in the first round;

[0044] Figure 10 This is a schematic diagram of the gantry crane fault detection and repair method provided in Embodiment 2 of the present invention.

[0045] In the diagram, 1-support mechanism, 2-crossbeam, 2-1-partition, 2-2-limiting groove, 2-3-wedge block, 3-positioning trolley, 3-1-top plate, 4-lifting equipment, 5-traveling trolley, 5-1-base, 6-first wheel assembly, 7-capacitive sensor, 8-second wheel assembly, 9-1-reinforced slider, 9-1-groove, 9-3-9-2-drive unit, 9-2-1-winch, 9-2-2-rope, 9-3-pin assembly, 9-3-1-support plate, 9-3 -2-Pin assembly, 9-3-2-1-Mounting base, 9-3-2-2-Lock tongue, 9-3-2-3-Spring, 9-3-3-Screw, 10-Wheelset changing device, 10-1-Transmission assembly, 10-1-1-Horizontal conveyor belt, 10-1-2-Vertical conveyor belt, 10-2-Connecting assembly, 10-2-1-Hydraulic fixing pin, 10-2-2-Hydraulic support rod, 10-2-3-Support frame, 10-2-4-Telescopic electrical connector, 10-2-5-Connecting rod. Detailed Implementation

[0046] The technical solutions of various embodiments of the present invention will be clearly and completely described in conjunction with 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, all other embodiments obtained by those skilled in the art without creative effort are part of the present invention.

[0047] Example 1

[0048] The gantry crane with self-healing function provided in this embodiment, such as Figures 1 to 2 As shown, it includes two symmetrically arranged support mechanisms 1, a crossbeam 2 mounted on the two support mechanisms, and a lifting device 4 slidably mounted on the crossbeam 2 via a positioning trolley 3. The support mechanisms 1 are mounted on a traveling trolley 5, and the lifting device 4 can be an electric hoist, etc. The gantry crane with self-repair function also includes a crossbeam bending detection device mounted on the positioning trolley, a wheel fault detection device mounted on the traveling trolley, a crossbeam reinforcement device 9 mounted inside the crossbeam, a wheelset replacement device 10 mounted on the traveling trolley, and a control system.

[0049] like Figures 4 to 5 As shown, the crossbeam 2 is hollow inside and divided into two parts by a partition 2-1 arranged along its length. The lower part has a groove along its length to facilitate the movement of the positioning trolley 3, and the upper part is used to accommodate the crossbeam reinforcement device 9. The wheels of the positioning trolley 3 are installed in the track provided by the groove, and its wheels are driven by a corresponding drive motor.

[0050] like Figures 2 to 3 As shown, the beam bending detection device consists of seven capacitors 7, which are installed along the length of the beam on the top plate 3-1 above the positioning trolley. This top plate and the partition plate 2-1 are fitted together with a clearance. The device also includes distance sensors installed at both ends of the traveling trolley to measure the distance between the trolley and the end of the beam, thus positioning the trolley. The capacitor sensors collect real-time data on the distance between themselves and the upper beam, detecting different locations as the trolley moves. By comparing the distance values ​​collected by the seven sensors, the deformation data of the current segment can be obtained. When a microcrack exists at a point on the beam, the mechanical properties of that section will decrease. When the trolley load passes over this point, the bending deformation will abnormally increase. Upon detecting this anomaly, the distance sensor data on the trolley is used to determine the location of the anomaly. The reinforcing slider is moved to the anomaly area to bear the load, and a prompt is issued to the operator, urging timely inspection of the beam.

[0051] like Figures 2 to 6As shown, the crossbeam reinforcement device 9 is used to reinforce and support the bending position of the crossbeam. It includes a reinforcement slider 9-1 and a drive unit 9-2 that slides the reinforcement slider inside the crossbeam. The drive unit 9-2 includes winches 9-2-1 installed at both ends of the crossbeam and ropes 9-2-2 wound on the winches. One end of the rope is fixedly connected to one side of the reinforcement slider. The two winches are respectively driven by a first drive motor, which drives the winches to rotate, thereby moving the reinforcement slider along the length of the crossbeam.

[0052] The reinforcing slider 9-1 has a groove 9-1-1 along its length. The crossbeam partition 2-1 protrudes upward, forming a track that fits the groove of the reinforcing slider. Two rows of limiting grooves 2-2 are formed on the contact surface between the inner side of the crossbeam and the reinforcing slider. Considering that the side of the crossbeam will bear a larger bending moment, the limiting grooves are formed on the inner upper surface of the crossbeam. Several wedge-shaped blocks 2-3 with the same structure are set in the limiting grooves, and the wedge-shaped blocks in the two rows of limiting grooves are inclined in opposite directions to restrict movement in two directions. Wedge-shaped blocks are used instead of straight grooves because if the position restriction is to be minimized, the groove density must be increased. However, if the straight grooves are denser, the distance between two adjacent grooves will be shortened, which may cause the partition between the grooves to collapse and the limiting to fail. Therefore, adjacent wedge-shaped grooves are used to increase the density while avoiding excessive degradation of mechanical properties.

[0053] The reinforcing slider 9-1 is locked to the crossbeam 2 by a pin assembly 9-3 disposed within the reinforcing slider cavity. The pin assembly 9-3 includes a support plate 9-3-1 and pins 9-3-2 mounted on the support plate. The support plate 9-3-1 is mounted within the reinforcing slider cavity by two lead screws 9-3-3, which drive the support plate to move up and down. Specifically, the support plate 9-3-1 is fixedly connected to a nut mounted on the lead screw, which is driven by a second drive motor. The second drive motor drives the lead screw to rotate, thereby moving the support plate up and down. When the pins push upward, they limit the movement; when they retract downward, they release the limit. There are two pins 9-3-2, and the end faces of the two pins are respectively adapted to the wedge-shaped blocks in the two rows of slots of the crossbeam. Furthermore, the pin 9-3-2 includes a mounting base 9-3-2-1 and a locking tongue 9-3-2-2 disposed within the mounting base. One end of the locking tongue is connected to the bottom of the mounting base via a spring 9-3-2-3, and the other end extends out of the mounting base and is adapted to the wedge blocks in the two rows of slots of the crossbeam. The spring inside the pin allows it to extend and retract within a certain range and conform to the wedge surface, thus ensuring that when the positioning pin extends, its position is always limited within the range shown in the figure.

[0054] like Figure 1 , Figure 2 , Figure 7As shown, the traveling trolley 5 includes a base 5-1 and a first wheelset assembly 6 mounted in mounting slots at both ends of the base 5-1. A wheel fault detection device is mounted on the wheels of the traveling trolley and is used to detect the wheel speed and / or the wheel drive motor current. The wheel fault detection device includes a speed sensor and / or a current detector. The speed sensor is mounted on the wheel and is used to detect the wheel speed. The current detector (e.g., a current clamp meter or a dynamic current sensor) is connected to the wheel drive motor and is used to detect the wheel drive motor current.

[0055] like Figures 7 to 9 As shown, the wheelset changing device 10 is installed on the traveling trolley and is used to realize online replacement of the traveling trolley wheelsets. It includes a second wheelset assembly 8, a conveying assembly 10-1 for conveying the second wheelset assembly 8, and a connecting assembly 10-2 for fixing the first wheelset assembly 6 or the second wheelset assembly 8 to the base.

[0056] The first wheelset assembly 6 and the second wheelset assembly 8 have the same structure. Taking the first wheelset assembly as an example, it includes a housing 6-1 and symmetrically arranged wheels 6-2 mounted on the bottom of the housing. The wheel drive motor for driving the wheels 6-2 is installed inside the housing 6-1. The two end faces of the housing are designed with strip-shaped toothed grooves 6-3, which mesh with the toothed grooves on the vertical conveyor belt.

[0057] The conveying assembly 10-1 includes a transverse conveyor belt 10-1-1 along the length of the base and a vertical conveyor belt 10-1-2 along the vertical direction. The transverse conveyor belt 10-1-1 is used to transport the second wheelset assembly to the base wheelset assembly mounting slot. There are two transverse conveyor belts, symmetrically arranged on the traveling trolley, with at least one being an active conveyor belt driven by a third drive motor connected to it. Photoelectric sensors are installed at the ends of the transverse conveyor belts to detect whether the second wheelset assembly has been conveyed to the correct position. The initial position of the second wheelset assembly can be at the middle of the transverse conveyor belt. The vertical conveyor belt 10-1-2 is used to transport the first wheelset assembly to the top of the base or to transport the second wheelset assembly into the base wheelset assembly mounting slot. Specifically, a vertical conveyor belt is installed on each of the two opposite sides of the wheelset assembly mounting slots at both ends of the base; at least one of the vertical conveyor belts is an active conveyor belt driven by a fourth drive motor connected to it.

[0058] The connecting assembly 10-2 includes hydraulic fixing pins 10-2-1, hydraulic support rods 10-2-2, support frames 10-2-3, and telescopic electrical connectors 10-2-4 symmetrically mounted on both sides of the base. The pin head of the hydraulic fixing pin 10-2-1 passes through the base and inserts into a groove on the surface of the second wheelset assembly housing. The hydraulic support rod 10-2-2 supports the base on the ground. The support frame 10-2-3 lifts the first wheelset assembly delivered to the top of the base; the support frame rotates via a hinge assembly; the hinge assembly includes a connecting rod 10-2-5 hinged to the side wall of the base, and a fifth drive motor driven by the connecting rod, which drives the connecting rod to rotate, thereby raising or retracting the support frame. The telescopic electrical connector 10-2-4 passes through the base and connects to the wheel drive motor and wheel fault detection device of the first or second wheelset assembly, providing power and transmitting signals.

[0059] The control system is connected to the beam bending detection device, wheel fault detection device, beam reinforcement device, and wheelset replacement device. It assesses beam or wheel faults based on the detection results from the beam bending detection device or wheel fault detection device, and controls the beam reinforcement device or wheelset replacement device based on the assessment results. The control system can be a PLC controller or a computer server. Specifically, the control system is connected to the positioning trolley, the traveling trolley, and the hoisting equipment, controlling their movements. The control system is electrically connected to the beam bending detection device, acquiring information from capacitive and distance sensors to detect the degree of beam bending and simultaneously position the positioning trolley. The control system is electrically connected to the wheel fault detection device, acquiring information from speed and current sensors to detect wheel operation. The control system is electrically connected to the beam reinforcement device, controlling the first and second drive motors to move the reinforcement slider to the reinforcement position and lock the slider. The control system is electrically connected to the wheelset changing device and controls the transmission assembly to transfer the second wheelset assembly. Simultaneously, it controls the hydraulic fixing pins, hydraulic support rods, and telescopic electrical joints of the connecting assembly to remove the first wheelset assembly and install and connect the second wheelset assembly. The control system operates in two modes: manned and unmanned. In manned mode, if a crossbeam or wheel malfunctions, the operator activates the crossbeam reinforcement device or the wheelset changing device. In unmanned mode, if a crossbeam or wheel malfunctions, the control system automatically activates the crossbeam reinforcement device or the wheelset changing device.

[0060] Example 2

[0061] This embodiment provides a fault detection and repair method applicable to the gantry crane in Embodiment 1, such as... Figure 10 As shown, it includes the following steps:

[0062] The S1 beam bending detection device and wheel fault detection device send the detection data to the control system in real time.

[0063] The beam bending detection device detects the bending of the crossbeam primarily by collecting capacitance data through several capacitive sensors and sending it to the control system. The crossbeam bending detection device also sends data from a distance measuring sensor mounted on a positioning trolley to the control system. The wheel fault detection device detects wheel operation, primarily by detecting wheel speed through a speed sensor and / or by detecting the drive motor current through a current detector, and sends the detection data to the control system.

[0064] Based on the received detection data, the S2 control system judges the degree of bending of the crossbeam and the operation of the wheels. If there is a fault in the crossbeam or the wheels, it proceeds to step S3; otherwise, it saves the detection data in real time and returns to step S1.

[0065] The control system uses received detection data to determine the degree of bending of the crossbeam and the operation of the wheels. For example, based on capacitance data collected by several capacitive sensors, the system can determine the degree of bending at the current position of the crossbeam. If the degree of bending exceeds a set threshold, a fault is determined to exist in the crossbeam at that position. The current position of the crossbeam can be determined by the control system using data measured by a distance sensor. The control system can also determine if there is a fault in the wheels based on wheel speed or detected drive current data. A fault is determined if the wheel speed exceeds the set range, stops, or changes abruptly; or if the detected change in drive motor current exceeds the set range, shows an abnormal increase in drive motor current, or is open-circuited.

[0066] S3 determines whether the control system is in unattended mode. If so, the gantry crane is stopped and the process proceeds to step S6; otherwise, the process proceeds to step S4.

[0067] The S4 control system alerts the operator that there is a fault in the crossbeam or / and wheels. The operator confirms the fault. If the fault is confirmed, proceed to step S5; otherwise, return to step S1.

[0068] S5 is initiated by the operator to stop the gantry crane and proceed to step S6.

[0069] Here, the operator mainly stops the gantry crane by using the control system to stop the lifting equipment, positioning trolley, and traveling trolley.

[0070] S6 initiates the repair process; the repair process includes a beam reinforcement process and / or a wheel assembly replacement process.

[0071] The beam reinforcement process is as follows: The control system first controls the first drive motor, which then sends the reinforcement slider to the location where the beam malfunctions. Then, it controls the second drive motor to lock the reinforcement slider to the beam.

[0072] The wheelset replacement process is as follows: The control system lowers the hydraulic support rod to the ground to support the base, then retracts the telescopic electrical connector to disconnect the electrical connection. Next, the hydraulic retaining pin retracts, releasing the first wheelset assembly. The vertical conveyor belt is activated, moving the first wheelset assembly upwards to the top. The support frame lifts the first wheelset assembly, allowing it to be removed. The second wheelset assembly is conveyed by the horizontal conveyor belt to the mounting slot on the base to be replaced. After passing completely through the photoelectric sensor, the second wheelset assembly rests on the support frame. The support frame retracts downwards and is then conveyed by the vertical conveyor belt to the installation position, which can be detected by an infrared sensor. The hydraulic retaining pin extends the plug and inserts it into the groove on the side of the second wheelset assembly, thus securing it to the base. The telescopic electrical connector is then connected to the second wheelset assembly (including the wheel drive motor and wheel fault detection device). Finally, the hydraulic support rod retracts, completing the wheelset replacement process.

[0073] The S7 repair process is complete. The gantry crane is restarted and the process returns to step S1.

[0074] This mainly involves restarting the hoisting equipment, positioning trolley, and traveling trolley to start the gantry crane's operation.

[0075] Those skilled in the art will recognize that the embodiments described herein are intended to help the reader understand the principles of the invention, and should be understood that the scope of protection of the invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations based on the technical teachings disclosed in this invention without departing from the spirit of the invention, and these modifications and combinations are still within the scope of protection of this invention.

Claims

1. A gantry crane having a self-repairing function, characterized by, The gantry crane includes two symmetrically arranged support mechanisms (1), a crossbeam (2) mounted on the two support mechanisms, and a hoisting device (4) slidably mounted on the crossbeam (2) via a positioning trolley (3). The support mechanisms (1) are mounted on a traveling trolley (5). The traveling trolley (5) includes a base (5-1) and first wheel assembly (6) mounted at both ends of the base (5-1). The gantry crane also includes: A beam bending detection device is installed on a positioning trolley (3) to detect the degree of bending of the beam at the position of the positioning trolley (3) on the beam. A wheel fault detection device is installed on the wheels of a traveling trolley to detect wheel speed and / or wheel drive motor current. A beam reinforcement device (9) includes a reinforcement slider (9-1) and a drive unit (9-2) that slides the reinforcement slider (9-1) inside the beam for reinforcing the beam at the bending position. The reinforcement slider (9-1) has a groove (9-1-1) along the length direction. The beam is hollow inside and is divided into two parts by a partition (2-1) along the length direction. The lower part has a groove along the length direction to facilitate the movement of the positioning trolley (3), and the upper part is used to accommodate the beam reinforcement device. The partition protrudes upward to form a track that matches the groove of the reinforcement slider. The drive unit (9-2) in the beam reinforcement device includes a winch (9-2-1) installed at both ends of the beam and a rope (9-2-2) wound on the winch. One end of the rope is fixedly connected to one side of the reinforcement slider. One of the components is connected to the first drive motor, which drives the winch to rotate, thereby moving the reinforcing slider along the length of the crossbeam. Two rows of limiting grooves (2-2) are provided on the inner side of the crossbeam where it contacts the reinforcing slider. Several wedge-shaped blocks (2-3) with identical structures are installed within these grooves, and the wedge-shaped blocks in the two rows of grooves are inclined in opposite directions. The reinforcing slider and the crossbeam are locked together by a pin assembly (9-3) located within the reinforcing slider cavity. The pin assembly (9-3) includes a support plate (9-3-1) and pins (9-3-2) mounted on the support plate. The support plate (9-3-1) is installed within the reinforcing slider cavity via a lead screw (9-3-3), which drives the support plate to move up and down. There are two pins, with their end faces respectively matching the wedge-shaped blocks in the two rows of grooves on the crossbeam. A wheelset replacement device (10) is installed on a traveling trolley to realize online replacement of the wheelsets of the traveling trolley. It includes a second wheelset assembly (8), a transmission assembly (10-1) for transmitting the second wheelset assembly (8), and a connection assembly (10-2) for fixing the first wheelset assembly (6) or the second wheelset assembly (8) to the base. The control system is connected to the beam bending detection device, the wheel fault detection device, the beam reinforcement device, and the wheelset replacement device, respectively. It is used to evaluate the beam or wheel faults based on the detection results of the beam bending detection device or the wheel fault detection device, and control the beam reinforcement device or the wheelset replacement device to operate based on the evaluation results.

2. The gantry crane having a self-repairing function according to claim 1, characterized in that, The beam bending detection device mainly consists of several capacitive sensors (7).

3. The gantry crane having a self-repairing function according to claim 1, characterized in that, The beam bending detection device also includes a distance sensor installed on the positioning trolley, used to measure the distance between the trolley and any end of the beam.

4. The gantry crane having a self-repairing function according to claim 1, characterized in that, The wheel fault detection device includes a speed sensor and / or a current detector. The speed sensor is installed on the wheel to detect the wheel speed, and the current detector is connected to the wheel drive motor to detect the wheel drive motor current.

5. The gantry crane having a self-repairing function according to claim 1, characterized in that, The first wheelset assembly (6) and the second wheelset assembly (8) have the same structure, including a housing and symmetrically arranged wheels mounted on the bottom of the housing; the conveying assembly (10-1) includes a transverse conveyor belt (10-1-1) along the length of the base and a vertical conveyor belt (10-1-2) along the vertical direction; the transverse conveyor belt is used to convey the second wheelset assembly to the base wheelset assembly mounting slot, and the vertical conveyor belt is used to convey the first wheelset assembly to the top of the base or to convey the second wheelset assembly into the base wheelset assembly mounting slot; the connecting assembly (10-2) includes hydraulic fixing pins (10-2) symmetrically mounted on both sides of the base. -1), hydraulic support rod (10-2-2), support frame (10-2-3), and telescopic electrical connector (10-2-4); the head of the hydraulic fixing pin (10-2-1) passes through the base and inserts into the groove on the surface of the second wheelset assembly housing; the hydraulic support rod (10-2-2) is used to support the base on the ground; the support frame (10-2-3) is used to lift the first wheelset assembly delivered to the top of the base; the support frame is driven to rotate through the hinge assembly; the telescopic electrical connector (10-2-4) passes through the base and is connected to the wheel drive motor and wheel fault detection device of the first wheelset assembly or the second wheelset assembly.

6. The gantry crane fault detection and repair method of any one of claims 1 to 5, wherein, Includes the following steps: The S1 beam bending detection device and wheel fault detection device send the detection data to the control system in real time. Based on the received detection data, the S2 control system judges the degree of bending of the crossbeam and the operation of the wheels. If there is a fault in the crossbeam or the wheels, it proceeds to step S3; otherwise, it saves the detection data in real time and returns to step S1. S3 determines whether the control system is in unattended mode. If yes, proceed to step S6; otherwise, proceed to step S4. The S4 control system alerts the operator that there is a fault in the crossbeam or / and wheels. The operator confirms the fault. If the fault is confirmed, proceed to step S5; otherwise, return to step S1. S5 is the operator stopping the gantry crane and proceeding to step S6; S6 initiates the repair process; the repair process includes a beam reinforcement process and / or a wheelset component replacement process. The S7 repair process is complete. The gantry crane is restarted and the process returns to step S1.

7. The gantry crane fault detection and repair method of claim 6, wherein, In step S6, the beam reinforcement process is as follows: The control system first controls the first drive motor, which then drives the reinforcement slider to the location where the beam failure occurs. Then, the control system controls the second drive motor to lock the reinforcement slider to the beam. The wheel assembly replacement process is as follows: The control system lowers the hydraulic support rod to the ground to support the base, then retracts the telescopic electrical connector to disconnect the electrical connection; next, the hydraulic fixing pin retracts, releasing the first wheel assembly from its fixation; the vertical conveyor belt is activated to move the first wheel assembly upwards to the top, and the support frame lifts the first wheel assembly for removal; the second wheel assembly is conveyed by the horizontal conveyor belt to the mounting slot of the base wheel assembly to be replaced, then by the vertical conveyor belt to the installation position; the hydraulic fixing pin is then used to fix the second wheel assembly to the base; the telescopic electrical connector is then connected to the second wheel assembly; finally, the hydraulic support rod is raised and retracted.

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