A method for collecting and calibrating a vertical angle of a boom of a luffing tower crane

Abstract

The application provides a jib crane vertical angle acquisition and calibration method, and belongs to the field of tower crane safety monitoring equipment. An acquisition device is arranged on the jib crane of the tower crane. The acquisition device is used to acquire the unique pulse value of each vertical angle position during the action of the jib crane of the tower crane. Then, the pulse value is calibrated by one key, and the vertical angle of the jib crane is calculated. A single high-precision encoder is installed at the root of the jib crane and the connection part of the tower crane. The action of the tower crane mechanism drives the jib crane to lift and lower. The jib crane drives the encoder connected with the transmission device to rotate. The safety monitoring equipment obtains the high-precision pulse value fed back by the encoder, so as to obtain the accurate value of the vertical angle of the jib crane.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of tower crane safety monitoring equipment, in particular to a method for collecting and calibrating the vertical angle of the jib of a tower crane. BACKGROUND

[0002] The existing method for collecting the vertical angle of the jib of a tower crane usually uses an angle sensor or an incremental rotary encoder installed on the transmission mechanism of the tower crane's counterweight arm.

[0003] The angle sensor is installed on the jib, and the collected vertical angle deviates greatly from the actual angle due to environmental temperature factors, especially when there is a strong magnetic field or the temperature is too high.

[0004] The encoder is installed on the transmission mechanism of the tower crane's counterweight arm, and the lifting and lowering of the jib is achieved by retracting and releasing the wire rope through the tower top support. In actual use, the change in the vertical angle is not linear with the length of the wire rope retracted or released, resulting in a deviation between the vertical angle calculated by the encoder output pulse value and the actual angle.

[0005] Therefore, the following problems exist:

[0006] (1) The output of the angle sensor usually changes without regard to the input when it is disturbed by external factors, which is called "temperature drift". The main reason for the drift is that the sensitivity element of the measurement system is usually susceptible to external temperature, humidity, electromagnetic interference, and the interference of the sensor conditioning circuit. This causes a deviation between the vertical angle of the jib and the actual angle, especially when there is a lot of electromagnetic interference around the device, the angle sensor cannot give a stable output.

[0007] The encoder is installed on the transmission mechanism, and the lifting and lowering of the jib is achieved by retracting and releasing the wire rope through the tower top support. In actual use, the length of the wire rope retracted or released is not linear with the change in the vertical angle of the jib, resulting in a deviation between the vertical angle calculated by the encoder output pulse value and the actual angle. This makes the horizontal range of the jib projection calculated by the vertical angle inaccurate, and further, the calculation of the lifting moment of the tower crane is not accurate, which may be larger or smaller than the actual value. When the tower crane is working in an overload or underload condition, the safety monitoring equipment cannot accurately determine the working condition, and the safety of the equipment cannot be guaranteed. SUMMARY

[0008] The present application aims to provide a method for collecting and calibrating the vertical angle of a boom of a tower crane, and solve the technical problem of inaccurate collection of the vertical angle of the boom by safety monitoring equipment caused by the installation mechanism of the angle sensor and the encoder.

[0009] In order to achieve the above-mentioned purpose, the technical solution adopted by the present application is as follows:

[0010] A method for collecting and calibrating the vertical angle of a boom of a tower crane, a collecting device is arranged on the boom of the tower crane, the collecting device is used to collect the unique pulse value of each vertical angle position during the action of the boom of the tower crane, and then the pulse value is calibrated by one key to calculate the vertical angle of the boom.

[0011] Further, the collecting device comprises a transmission device, an encoder fixing device and an encoder, the transmission device is fixed to the boom of the tower crane by using a first bolt, the encoder is fixed to the encoder fixing device by using a third bolt, the encoder fixing device is fixed to the fixing plane of the tower crane by using a second bolt, and the encoder is connected to the transmission shaft of the transmission device by using a split pin.

[0012] Further, the transmission device is installed on the lug plate at the connection part between the root of the boom of the tower crane and the tower crane, the transmission shaft is a fixed component welded on the bent plate, the boom rotates, the transmission device moves with the boom, and the rotation data of the boom is output by the transmission shaft.

[0013] Further, the encoder fixing device is used to install the encoder required for collecting the vertical angle data of the boom on the fixing plane of the tower crane, and the encoder is used to connect the transmission shaft and output the pulse generated during the rotation of the boom to the collector of the safety monitoring system.

[0014] Further, the one-key calibration is performed by the boom vertical angle one-key calibration button in the display screen interface of the safety monitoring system.

[0015] Further, the encoder is connected to the transmission shaft of the transmission device by using a split pin, the transmission shaft of the transmission device rotates with the boom during the lifting and lowering of the boom, the encoder shaft performs angular displacement, and the unique pulse value of each vertical angle position during the action of the boom of the tower crane is output, the vertical angle of the boom can be accurately calculated by using the algorithm after one-key calibration by the safety monitoring system.

[0016] Further, through the connection of the transmission shaft of the transmission device and the encoder, the lifting or lowering of the boom tower crane's lifting boom realizes the angular displacement of the encoder shaft, and the output real-time changing pulse value, in use, the safety monitoring system collector is responsible for receiving the feedback value of the encoder, when installing the encoder, it is determined whether the feedback value of the encoder is increased or decreased when the boom tower crane's lifting boom is lifted or lowered, after the installation of the acquisition device is completed, the boom tower crane is lifted or lowered to a fixed angle, and a one-key calibration button is pressed on the display screen, and through the algorithm, the one-key calibration function can be realized.

[0017] Further, the specific process of calculating the vertical angle of the lifting boom is as follows:

[0018] The one-key calibration point angle is defined as the vertical angle, the pulse value of the encoder feedback at the vertical angle is A, the pulse number of the encoder changes when the vertical angle changes by 0.1° is K, the real-time vertical angle of the boom tower crane's lifting boom is α, the real-time pulse value of the encoder is B, a single-turn encoder with a resolution of N is adopted, that is, the encoder outputs N pulse values when it rotates one turn, and one turn of the encoder is defined as an angle of 360°, the accuracy of the vertical angle is 0.1°, and the pulse number of the encoder output at 0.1° is calculated as K=N / 3600.

[0019] Through the angle display board of the external machine, one-key calibration is performed at the vertical angle of the boom tower crane's lifting boom, the one-key calibration button on the screen is clicked, the safety monitoring system collector records the current encoding value A feedback by the encoder, and the real-time pulse value of the encoder is B during the lifting or lowering of the lifting boom; the vertical angle α of the lifting boom is calculated as α=15±(B-A) / 10K.

[0020] The present application has the following beneficial effects due to the adoption of the above technical solutions:

[0021] (1) The present application adopts a single-turn high-precision encoder installed at the root of the lifting boom and the connection part of the boom tower crane, the movement of the boom tower crane mechanism drives the lifting boom to be lifted and lowered, the boom drives the encoder connected with the transmission device to rotate, and the safety monitoring device obtains the high-precision pulse value feedback by the encoder, thereby obtaining the accurate value of the vertical angle of the lifting boom;

[0022] (2) By adopting a high-precision single-turn encoder, and through the single-turn maximum pulse value of the encoder corresponding to an angle value of 360°, the pulse number corresponding to an angle of 0.1° is converted, on this basis, the vertical angle of the lifting boom only needs to be single-point one-key calibrated at 15°, so as to determine the pulse range corresponding to the working angle 15°-85° of the boom tower crane's lifting boom, realize the real-time acquisition of the working angle of the boom tower crane's lifting boom, and thereby accurately calculate the horizontal projection amplitude of the boom tower crane, and ensure the accuracy of the calculation of the lifting moment;

[0023] (3) It not only achieves accurate acquisition of the vertical angle of the boom of the luffing tower crane and simplifies the calibration, but also avoids overload operation of the tower crane mechanism, effectively protecting the safety of personnel, equipment and property. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the luffing jib tower crane of the present invention;

[0025] Figure 2 yes Figure 1 Enlarged front view at point A;

[0026] Figure 3 yes Figure 1 Enlarged structural diagram at point A in the middle;

[0027] Figure 4 yes Figure 1 Enlarged top view at point A in the middle;

[0028] Figure 5 This is a block diagram illustrating the acquisition principle of this invention.

[0029] In the attached diagram, 1-lamp tower crane boom, 2-transmission device, 3-first bolt, 4-encoder fixing device, 5-second bolt, 6-fixed plane, 7-encoder, 8-third bolt, and 9-cotter pin. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and preferred embodiments. However, it should be noted that many details listed in the specification are merely to provide the reader with a thorough understanding of one or more aspects of the present invention, and these aspects of the invention can be implemented even without these specific details.

[0031] like Figures 1-2 As shown, a method for acquiring and calibrating the vertical angle of a luffing tower crane boom is described. The method involves acquiring data using an acquisition device, then calibrating the angle using a calibration method, and finally calculating the vertical angle.

[0032] The data acquisition device includes a transmission device, an encoder fixing device, and an encoder; the calibration method includes a one-click calibration method in the safety monitoring system and a method for calculating the vertical angle of the crane boom after calibration.

[0033] (1) The transmission device is installed on the ear plate at the connection between the root of the boom of the luffing tower crane and the tower crane. The transmission shaft is a fixed component welded to the bending plate. When the boom rotates, the transmission device moves with the boom and outputs the rotation data of the boom through the transmission shaft.

[0034] (2) The encoder fixing device is used to mount the encoder required for collecting the vertical angle data of the crane jib frame on the fixed plane or structure of the tower crane itself;

[0035] (3) The encoder is used to connect the transmission shaft and output the pulses generated in the rotation process of the crane jib frame to the safety monitoring system collector;

[0036] (4) The one-key calibration mode is a one-key calibration button of the vertical angle of the crane jib frame in the display screen interface of the safety monitoring system;

[0037] (5) The vertical angle calculation method of the crane jib frame is an algorithm formula of the vertical angle of the crane jib frame in the safety monitoring system, which is used to calculate the pulse value fed back by the encoder and output the vertical angle of the crane jib frame.

[0038] The encoder is connected with the transmission shaft of the transmission device by means of the split pin, and in the lifting and lowering process of the crane jib frame, the transmission shaft of the transmission device rotates with the crane jib frame, and the encoder shaft performs angular displacement, and outputs the unique pulse value of each vertical angle position in the action process of the jib crane tower crane, and after one-key calibration by the safety monitoring system, the vertical angle of the crane jib frame can be accurately calculated through algorithm calculation.

[0039] The calibration method includes the one-key calibration mode in the safety monitoring system and the calculation method of the vertical angle of the crane jib frame after calibration.

[0040] The transmission device and the encoder fixing device are sheet metal bending plates.

[0041] The optional resolution of the encoder is 4096 single-turn encoders.

[0042] The transmission device 2 is fixed on the crane jib frame 1 of the jib crane tower crane by means of the bolts 3, the encoder 7 is fixed on the encoder fixing device 4 by means of the bolts 8, the encoder fixing device 4 is fixed on the fixed plane or structure 6 of the tower crane itself by means of the bolts 5, and the encoder 7 is connected with the transmission shaft 10 on the transmission device 2 by means of the split pin 9.

[0043] In this example, the lifting or lowering of the crane jib frame 1 of the jib crane tower crane realizes the angular displacement of the encoder shaft through the connection of the transmission shaft 10 of the transmission device 2 and the encoder 7, and outputs the real-time changing pulse value. In use, the safety monitoring system collector is responsible for receiving the feedback value of the encoder, and when the encoder 7 is installed, it is determined whether the feedback value of the encoder increases or decreases when the crane jib frame of the jib crane tower crane is lifted or lowered, and after the installation of the collection device, the crane jib frame is lifted or lowered to a fixed angle (15° in this example), and the one-key calibration button is pressed on the display screen, and the one-key calibration function can be realized through the algorithm. The algorithm is as follows:

[0044] The key calibration point angle is defined as a vertical angle of 15°, the pulse value fed back by the encoder at 15° is A, the pulse number of the encoder changed when the vertical angle changes by 0.1° is K, the real-time vertical angle of the boom of the tower crane is α, and the real-time pulse value of the encoder is B.

[0045] (1) A single-turn encoder with a resolution of 4096 is adopted, that is, the encoder outputs 4096 pulse values when rotating one circle, the rotation of the encoder one circle is defined as an angle of 360°, the precision of the vertical angle is 0.1°, and the pulse number of the encoder output at 0.1° is calculated as K=4096 / 3600;

[0046] (2) The one-key calibration is performed at 15° of the boom of the tower crane through an external mechanical angle display board, the one-key calibration button on the screen is clicked, and the current encoding value A fed back by the encoder is recorded by the safety monitoring system collector;

[0047] (3) The real-time pulse value of the encoder is B during the lifting or lowering of the boom;

[0048] (4) α is calculated as α=15±(B-A) / 10K;

[0049] The above acquisition mode, calibration method and algorithm are a specific embodiment of a boom vertical angle acquisition mode and calibration method scheme of a tower crane. Finally, the real-time vertical angle value of the boom of the tower crane is displayed on the display screen, the accurate calculation of the vertical angle and the horizontal projection amplitude of the tower crane is realized, the real-time lifting torque value of the tower crane is further accurately calculated, and the safe use of the tower crane is ensured.

[0050] The application is different from the current boom vertical angle which adopts an angle sensor or an encoder installed on a balance arm mechanism of the tower crane. The application adopts a single-turn high-precision encoder installed at the root of the boom and the connection part of the tower crane, the movement of the tower crane mechanism drives the lifting and lowering of the boom, the boom drives the rotation of the encoder connected with the transmission device, the safety monitoring device obtains the high-precision pulse value fed back by the encoder, and thus the accurate value of the vertical angle of the boom is obtained.

[0051] The above is only a preferred embodiment of the application, and it should be noted that, for those skilled in the art, some improvements and refinements can be made without departing from the principles of the application, and these improvements and refinements should also be regarded as the protection scope of the application.

Claims

1. A method for collecting and calibrating the vertical angle of a boom of a luffing tower crane, characterized in that: The collecting device is arranged on the jib crane of the tower crane, and is used for collecting a unique pulse value of each vertical angle position in the action process of the jib crane of the tower crane, and then calculating the vertical angle of the jib crane after one-key calibration of the pulse value; The collecting device comprises a transmission device, an encoder fixing device and an encoder. The transmission device is fixed on the jib crane of the tower crane by a first bolt. The encoder is fixed on the encoder fixing device by a third bolt. The encoder fixing device is fixed on a fixed plane of the tower crane by a second bolt. The encoder is connected with a transmission shaft of the transmission device by a split pin. The one-key calibration is calibration of a one-key calibration button of the jib crane vertical angle in a display screen interface of the safety monitoring system. In the process of lifting and lowering of the jib crane, the transmission shaft of the transmission device rotates with the jib crane, and the encoder shaft performs angular displacement to output the unique pulse value of each vertical angle position in the action process of the jib crane of the tower crane. After one-key calibration by the safety monitoring system, the vertical angle of the jib crane can be accurately calculated by algorithm. Through the connection of the transmission shaft of the transmission device and the encoder, the lifting or lowering of the jib crane of the tower crane realizes the angular displacement of the encoder shaft to output the real-time changing pulse value. In use, the safety monitoring system collector is responsible for receiving the feedback value of the encoder. When the encoder is installed, it is determined whether the feedback value of the encoder is increased or decreased when the jib crane of the tower crane is lifted or lowered. After the installation of the collecting device, the jib crane of the tower crane is lifted or lowered to a fixed angle. The one-key calibration button is pressed on the display screen. The one-key calibration function can be realized through the algorithm.

2. The method for collecting and calibrating the vertical angle of the boom of a luffing tower crane according to claim 1, characterized in that: The transmission device is installed on the lug plate at the connection position between the root of the jib crane of the tower crane and the tower crane. The transmission shaft is a fixed component welded on the bent plate. When the jib crane rotates, the transmission device moves with the jib crane to output the rotation data of the jib crane.

3. The method for collecting and calibrating the vertical angle of a boom of a luffing tower crane according to claim 1, characterized in that The encoder fixing device is used for installing the encoder required for collecting the vertical angle data of the jib crane on the fixed plane of the tower crane. The encoder is used for connecting the transmission shaft and outputting the pulse generated in the rotation process of the jib crane to the collector of the safety monitoring system.

4. The method for collecting and calibrating the vertical angle of the boom of a luffing tower crane according to claim 1, characterized in that: The specific process of calculating the vertical angle of the jib crane is as follows: The one-key calibration point angle is defined as the vertical angle. The pulse value fed back by the encoder at the vertical angle is A. The pulse number of the encoder changed when the vertical angle changes by 0.1° is K. The real-time vertical angle of the jib crane of the tower crane is α. The real-time pulse value of the encoder is B. The single-turn encoder with resolution N is adopted, which means that the encoder outputs N pulse values when rotating one turn. One turn of the encoder is defined as an angle of 360°. The accuracy of the vertical angle is 0.1°. The pulse number output by the encoder when the vertical angle changes by 0.1° is calculated as K=N / 3600. By the external mechanical angle display board, one-key calibration is carried out when the vertical angle of the boom tower crane jib is calibrated, a one-key calibration button on the screen is clicked, the current encoder feedback pulse value A is recorded by the safety monitoring system collector, in the process of lifting or lowering the jib, the real-time pulse value of the encoder is B; the vertical angle α of the jib is calculated as α=15±(B-A) / 10K.

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