Gantry crane positioning method and apparatus

Abstract

The application provides a gantry crane positioning method and device. The method comprises the following steps: obtaining the pulse direction of the pulse sent by an encoder, and accumulating the pulse quantity corresponding to each pulse direction; determining the moving direction of the gantry crane based on the pulse direction, and determining the moving distance of the gantry crane in each moving direction based on the pulse quantity corresponding to each pulse direction; and determining the position information of the hoisted heavy object based on the moving distance of the gantry crane in each moving direction. The application can monitor the position information of the hoisted heavy object in real time, so as to ensure hoisting safety.

Description

Technical Field

[0001] This invention relates to the field of automation control technology, and in particular to a gantry crane positioning method and equipment. Background Technology

[0002] Gantry cranes, also known as portal cranes, are widely used in transportation and construction for lifting heavy objects. Tracks are laid within the lifting area. The gantry crane's body can move along the tracks via a trolley, the overhead trolley can move along its own track, and the hook can move vertically up and down via a wire rope reel. By moving the crane body, the overhead trolley, and the hook, the spatial movement of the lifted object is accomplished.

[0003] However, most gantry cranes are not equipped with position monitoring functions when they leave the factory. This means that the gantry crane can only move the lifted load in space, but cannot monitor the position information of the lifted load in real time. When there are a large number of piled-up objects in the lifting site, if the position information of the lifted load cannot be monitored in real time, collision accidents may occur during the lifting process, affecting lifting safety. Summary of the Invention

[0004] This invention provides a gantry crane positioning method and equipment to solve the problem of not being able to monitor the position information of the lifted load in real time.

[0005] In a first aspect, embodiments of the present invention provide a gantry crane positioning method, applied to a controller in a gantry crane positioning device, wherein the gantry crane positioning device further includes an encoder and a mounting mechanism, the encoder being connected to the motion mechanism of the gantry crane via the mounting mechanism, and the encoder moving synchronously with the motion mechanism; the method includes:

[0006] Obtain the pulse direction of the pulses sent by the encoder, and accumulate the number of pulses corresponding to each pulse direction;

[0007] Based on the pulse direction, the moving direction of the gantry crane is determined, and based on the number of pulses corresponding to each pulse direction, the moving distance of the gantry crane in each moving direction is determined;

[0008] Based on the moving distance of the gantry crane in each direction of movement, the position information of the lifted load is determined.

[0009] In one possible implementation, the motion mechanism includes: a trolley or an overhead crane;

[0010] Based on the number of pulses corresponding to each pulse direction, the traveling distance of the gantry crane in each moving direction is determined, including:

[0011] When the gantry crane positioning device is connected to the gantry crane's trolley or overhead crane, according to Calculate the distance the gantry crane travels in each direction of movement;

[0012] Where l represents the distance the gantry crane travels in the current direction, C1 represents the circumference of the first rolling wheel, N represents the number of pulses output by the encoder per revolution, and P represents the number of pulses corresponding to the current pulse direction.

[0013] In one possible implementation, the motion mechanism includes a wire rope reel;

[0014] Based on the number of pulses corresponding to each pulse direction, the traveling distance of the gantry crane in each moving direction is determined, including:

[0015] When the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel is not using a movable pulley, according to Calculate the distance the gantry crane travels in each direction of movement;

[0016] Where l represents the distance the gantry crane moves in the current direction, C3 represents the circumference of the shaft of the wire rope reel, P represents the number of pulses corresponding to the current pulse direction, C2 represents the circumference of the friction disc at any end of the wire rope reel, C1 represents the circumference of the first rolling wheel, and N represents the number of pulses output by the encoder for each revolution.

[0017] Alternatively, when the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel uses M sets of movable pulleys, according to... Calculate the distance the gantry crane travels in each direction of movement.

[0018] In one possible implementation, magnetic devices are installed at a first preset position on the upper surface of the gantry crane track and at a second preset position on the upper surface of the overhead crane moving track, and a sensor is installed at a third preset position on the gantry crane positioning device; the method further includes:

[0019] When a sensing signal is received from the sensor, the pulse count and position information corresponding to the sensor are cleared to zero.

[0020] In one possible implementation, the location information includes the lifting height, and the method further includes:

[0021] When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook is obtained;

[0022] Based on the lifting weight, determine the height information of the lifted object;

[0023] Based on the height information, the lifting height of the suspended object is updated, and the pulse count corresponding to the wire rope reel is cleared to zero.

[0024] In one possible implementation, the mounting mechanism includes a bracket, a first mounting plate, a first rolling wheel, and a first pressure spring;

[0025] The first end of the bracket is used to fix and connect the motion mechanism of the gantry crane, and the second end of the bracket is perpendicularly connected to one end of the first mounting plate;

[0026] The other end of the first mounting plate is provided with a first through hole, the encoder and the first rolling wheel are respectively disposed on both sides of the other end of the first mounting plate, and the rotating shaft of the encoder is fixedly connected to the center position of the first rolling wheel through the first through hole;

[0027] The two ends of the first pressure spring are respectively connected to the second end of the bracket and the other end of the first mounting plate to adjust the tilt angle of the first mounting plate so that the first rolling wheel rubs and rolls along the rolling surface.

[0028] In one possible implementation, the gantry crane positioning device further includes a pressure sensor and a temperature sensor, the pressure sensor and the temperature sensor being mounted on the hook of the gantry crane; the method further includes:

[0029] When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook, as well as the current initial air pressure and initial temperature values, are obtained.

[0030] Real-time air pressure and temperature values ​​are acquired during the lifting process, and the direction and distance of movement of the lifted load are determined based on the real-time air pressure, real-time temperature, initial air pressure, and initial temperature values.

[0031] Based on the lifting weight, the height information of the lifted object is determined, and based on the height information, the direction of movement, and the distance of movement, the lifting height of the lifted object is determined.

[0032] Secondly, embodiments of the present invention provide a gantry crane positioning device, including: an encoder, a mounting mechanism, and a controller;

[0033] The encoder is connected to the motion mechanism of the gantry crane via the mounting mechanism, and the encoder moves synchronously with the motion mechanism.

[0034] The controller is electrically connected to the encoder and is used to acquire the pulse direction of the pulses sent by the encoder and accumulate the number of pulses corresponding to each pulse direction; based on the pulse direction, the controller determines the moving direction of the gantry crane and, based on the number of pulses corresponding to each pulse direction, determines the moving distance of the gantry crane in each moving direction; based on the moving distance of the gantry crane in each moving direction, the controller determines the position information of the lifted load.

[0035] In one possible implementation, the mounting mechanism includes a bracket, a first mounting plate, a first rolling wheel, and a first pressure spring;

[0036] The first end of the bracket is used to fix and connect the motion mechanism of the gantry crane, and the second end of the bracket is vertically connected to one end of the first mounting plate; the other end of the first mounting plate is provided with a first through hole.

[0037] The encoder and the first rolling wheel are respectively disposed on both sides of the other end of the first mounting plate, and the rotating shaft of the encoder is fixedly connected to the center position of the first rolling wheel through the first through hole;

[0038] The two ends of the first pressure spring are respectively connected to the second end of the bracket and the other end of the first mounting plate to adjust the tilt angle of the first mounting plate so that the first rolling wheel rubs and rolls along the rolling surface.

[0039] In one possible implementation, the gantry crane positioning device further includes: a second mounting plate, a generator, a second rolling wheel, a second pressure spring, and an energy storage device;

[0040] One end of the second mounting plate is vertically connected to the third end of the bracket, and the other end of the second mounting plate is provided with a second through hole;

[0041] The generator and the second rolling wheel are respectively disposed on both sides of the other end of the second mounting plate, and the rotating shaft of the generator is fixedly connected to the center position of the second rolling wheel through the second through hole;

[0042] The two ends of the second pressure spring are respectively connected to the third end of the bracket and the other end of the second mounting plate to adjust the tilt angle of the second mounting plate so that the second rolling wheel rubs and rolls along the rolling surface;

[0043] The energy storage device is electrically connected to both the generator and the controller.

[0044] This invention provides a gantry crane positioning method and device. By fixing each gantry crane positioning device to each moving mechanism of the gantry crane, the encoder in each gantry crane positioning device can move synchronously with each moving mechanism and output pulse signals accordingly. This allows the controller in each gantry crane positioning device to calculate the moving distance of each moving mechanism in different moving directions based on the pulse signals, and finally determine the position information of the lifted load, thus achieving the purpose of real-time monitoring of the spatial position of the lifted load. Attached Figure Description

[0045] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0046] Figure 1 This is an application scenario diagram of the gantry crane positioning method provided in the embodiments of the present invention;

[0047] Figure 2 This is a schematic diagram of the structure of a gantry crane positioning device provided in an embodiment of the present invention, which is installed on a gantry crane track or an overhead crane moving track;

[0048] Figure 3 This is a schematic diagram of the structure of the gantry crane positioning device provided in an embodiment of the present invention, which is disposed on the upper surface of the friction disc;

[0049] Figure 4 This is a detailed enlarged view of the gantry crane positioning device provided in an embodiment of the present invention;

[0050] Figure 5 This is an electrical schematic diagram of the gantry crane positioning device provided in an embodiment of the present invention;

[0051] Figure 6 This is a flowchart illustrating the implementation of the gantry crane positioning method provided in this embodiment of the invention;

[0052] Figure 7 This is a schematic diagram of the gantry crane positioning device provided in an embodiment of the present invention;

[0053] Figure 8 This is a schematic diagram of the controller provided in an embodiment of the present invention. Detailed Implementation

[0054] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of the invention. However, those skilled in the art will understand that the invention can be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods are omitted so as not to obscure the description of the invention with unnecessary detail.

[0055] The inventors have discovered that most gantry cranes are not equipped with position information monitoring functions when they leave the factory. This means that gantry cranes can only move the lifted load in space, but cannot monitor the position information of the lifted load in real time. When there are a large number of piled-up objects in the lifting site, if the position information of the lifted load cannot be monitored in real time, collision accidents may occur during the lifting process, affecting lifting safety.

[0056] To ensure lifting safety by monitoring the position of the lifted load in real time, this application employs a real-time method where an encoder is connected to the motion mechanism of the gantry crane via an installation structure. This allows the encoder to move synchronously with the gantry crane's motion mechanism. During movement, the encoder sends pulse signals in real time, enabling the controller to determine the gantry crane's direction and distance of movement, thereby determining the current position of the lifted load and achieving real-time monitoring of its spatial location.

[0057] To make the objectives, technical solutions, and advantages of the present invention clearer, specific embodiments will be described below in conjunction with the accompanying drawings.

[0058] First, see Figure 1 The gantry crane's body moves along the gantry crane track via a trolley. The overhead crane on the gantry crane moves along the overhead crane track. The hook on the gantry crane is connected to the wire rope on the wire rope reel; by rotating the wire rope reel, the hook can move vertically. By moving the trolley and overhead crane, and rotating the wire rope reel, the spatial movement of the lifted load is completed. In this embodiment of the invention, the position information can be coordinate information. Coordinate representation can accurately describe the position information of the lifted load. This embodiment of the invention establishes a spatial coordinate system based on the gantry crane equipment to determine the spatial coordinates of the lifted load, thereby clarifying the position information of the lifted load. For example, the gantry crane track direction is the X-axis, the overhead crane track direction is the Y-axis, and the vertical direction is the Z-axis.

[0059] This invention provides a gantry crane positioning device. The gantry crane positioning device is installed at different positions on the gantry crane and connected to each of its moving mechanisms. It is used to determine the direction and distance of movement of each moving mechanism, thereby determining the spatial coordinates of the lifted load. The gantry crane positioning device includes an encoder, a mounting mechanism, and a controller. The encoder is connected to the moving mechanism of the gantry crane via the mounting mechanism, enabling the encoder to move synchronously with the moving mechanism. During movement, the encoder sends pulse signals in real time. Based on the pulse signals sent by the encoder, the controller determines the direction and distance of movement of the moving mechanism, thereby determining the spatial coordinates of the lifted load.

[0060] See Figure 2 and Figure 3 The gantry crane positioning devices are respectively installed on the upper surface of the gantry crane track, the upper surface of the overhead crane moving track, and the upper surface of the friction disc at either end of the wire rope reel. The gantry crane positioning device installed on the upper surface of the gantry crane track is connected to the gantry crane trolley and is used to determine the coordinates of the lifted load on the X-axis. The gantry crane positioning device installed on the upper surface of the overhead crane moving track is connected to the gantry crane trolley and is used to determine the coordinates of the lifted load on the Y-axis. The gantry crane positioning device installed on the upper surface of the friction disc at either end of the wire rope reel is connected to the wire rope reel and is used to determine the coordinates of the lifted load on the Z-axis.

[0061] Please refer to the above. Figure 2 , Figure 3 and Figure 4 The gantry crane positioning device includes: an installation mechanism, an encoder 20, and a controller (not shown in the figure). The installation mechanism includes: a bracket 21, a first mounting plate 22, a first rolling wheel 23, and a first pressure spring 24.

[0062] The first end of the bracket 21 is used to fix and connect the motion mechanism of the gantry crane, and the second end of the bracket 21 is vertically connected to one end of the first mounting plate 22; the other end of the first mounting plate 22 is provided with a first through hole.

[0063] The encoder 20 and the first roller 23 are respectively disposed on both sides of the other end of the first mounting plate 22, and the rotating shaft of the encoder 20 is fixedly connected to the center position of the first roller 23 through the first through hole;

[0064] The two ends of the first pressure spring 24 are respectively connected to the second end of the bracket 21 and the other end of the first mounting plate 22 to adjust the tilt angle of the first mounting plate 22 so that the first rolling wheel 23 rolls along the rolling surface.

[0065] The controller is electrically connected to the encoder to obtain the pulse direction of the pulses sent by the encoder and accumulate the number of pulses corresponding to each pulse direction; based on the pulse direction, the moving direction of the gantry crane is determined, and based on the number of pulses corresponding to each pulse direction, the moving distance of the gantry crane in each moving direction is determined; based on the moving distance of the gantry crane in each moving direction, the spatial coordinates of the lifted load are determined.

[0066] As described above, the motion mechanism of the gantry crane includes a trolley, a crane, or a wire rope reel. The first end of the bracket in each gantry crane positioning device is connected to the trolley, crane, and wire rope reel, respectively. Correspondingly, the rolling surface includes the upper surface of the gantry crane track, the upper surface of the crane moving track, or the upper surface of the friction disc at either end of the wire rope reel. See also... Figure 2 and Figure 4 When the trolley or overhead crane moves, the trolley or overhead crane, via bracket 21, drives the first rolling wheel 23 to roll along the upper surface of the gantry crane track or the upper surface of the crane's moving track. Simultaneously, the first rolling wheel 23 drives the encoder 20 to rotate coaxially. The encoder 20 sends pulses in real time during rotation. The controller receives the pulses sent by the encoder 20 and determines the direction and distance of movement of the trolley or overhead crane based on the pulses, thereby determining the coordinates of the lifted load on the X and Y axes. Similarly, see... Figure 3 and Figure 4 When the wire rope reel rotates, the reel, via bracket 21, drives the first rolling wheel 23 to roll along the upper surface of the friction disc at either end of the reel. The first rolling wheel 23 correspondingly drives the encoder 20 to rotate coaxially. The encoder 20 sends pulses in real time during rotation. The controller receives the pulses sent by the encoder 20 and determines the rotation direction and distance of the wire rope reel based on these pulses, thereby determining the coordinates of the lifted load on the Z-axis.

[0067] Furthermore, in this embodiment of the invention, a first pressure spring 24 is provided to adjust the tilt angle of the first mounting plate 22, thereby ensuring that the first rolling wheel 23 can contact the rolling surface and follow the bracket 21 to roll along the rolling surface. Simultaneously, it also prevents wear on the first mounting plate, the gantry crane track, the overhead crane moving track, and the friction disc.

[0068] In some embodiments, see Figure 2 and Figure 3 The gantry crane positioning device also includes: a second mounting plate 32, a generator 33, a second rolling wheel 34, a second pressure spring 35, and an energy storage device (not shown in the figure).

[0069] One end of the second mounting plate 32 is vertically connected to the third end of the bracket 21, and the other end of the second mounting plate 32 is provided with a second through hole;

[0070] The generator 33 and the second roller 34 are respectively disposed on both sides of the other end of the second mounting plate 32, and the rotating shaft of the generator 33 is fixedly connected to the center position of the second roller 34 through the second through hole;

[0071] The two ends of the second pressure spring 35 are respectively connected to the third end of the bracket 21 and the other end of the second mounting plate 32 to adjust the tilt angle of the second mounting plate 32 so that the second rolling wheel 34 rubs and rolls along the rolling surface.

[0072] The energy storage device is electrically connected to both the generator and the controller.

[0073] This invention considers that the gantry crane positioning device moves accordingly during the lifting of heavy objects. This necessitates that the power supply cable for the gantry crane positioning device be of sufficient length to ensure that the positioning device can move in tandem with the gantry crane's motion mechanism. However, excessively long power supply cables can lead to cable entanglement and interfere with the movement of the positioning device. To solve this problem, this invention provides a second mounting plate 32 at the third end of the bracket 21 of the gantry crane positioning device, and coaxially fixes a second rolling wheel 34 and a generator 33 at the other end of the second mounting plate 32. This allows the generator 33 to rotate synchronously and generate electricity during the movement of the gantry crane. The electrical energy generated by the generator is stored in an energy storage device and continuously supplies power to the controller. The controller can also power the encoder. Similarly, a second pressure spring 35 is used to adjust the tilt of the second mounting plate 32 to ensure that the second rolling wheel 34 can roll along the rolling surface along with the bracket 21.

[0074] See Figure 5 In this embodiment of the invention, a voltage stabilizing circuit can also be installed in the gantry crane positioning device. During the movement and lifting of the heavy object by the gantry crane, the first and second rolling wheels are driven to rotate synchronously via the support frame. The second rolling wheel drives the generator to rotate, generating electrical energy, which is output to the energy storage device via the voltage stabilizing circuit. The energy storage device provides uninterrupted power to the controller. The first rolling wheel drives the encoder to rotate, thereby outputting pulses. The controller calculates the coordinate values ​​on the current coordinate axis in real time based on the pulses and reports them to the control center via wireless transmission.

[0075] When the gantry crane moves, pulse signals are output at high speed, and the generator's output power increases accordingly, allowing the controller to report coordinate values ​​at a higher frequency. When the gantry crane is stationary, the pulse signals essentially disappear, the generator stops generating electricity, and the controller primarily relies on the pre-stored electrical energy from the energy storage device. At this time, the transmission frequency can be reduced, thereby significantly increasing the system's standby time. For example, the energy storage device can be a lithium battery.

[0076] Compared to existing technologies, this invention connects the encoder to the motion mechanism of the gantry crane via a mounting mechanism, enabling the encoder to move synchronously with the motion mechanism. The encoder generates pulses in real time during movement, allowing the controller to determine the gantry crane's direction and distance of movement based on these pulses, and thus determine the coordinates of the lifted load on the current coordinate axis. Furthermore, by installing gantry crane positioning devices at different locations on the gantry crane, the spatial coordinates of the lifted load are determined, ultimately achieving the goal of real-time monitoring of the lifted load's position information.

[0077] In this embodiment of the invention, the first end of the bracket is fixedly connected to the motion mechanism of the gantry crane, and the second end of the bracket is fixedly connected to the encoder and the first rolling wheel. This allows the motion mechanism of the gantry crane to drive the first rolling wheel to rotate through friction via the bracket, thereby driving the encoder to rotate, so as to ensure that the encoder can move synchronously with the motion mechanism.

[0078] Meanwhile, to avoid the problem of cable tangling and obstruction of the gantry crane positioning equipment due to excessively long power supply cables, this embodiment of the invention fixes one end of the second mounting plate to the third end of the bracket, and coaxially connects the generator and the second rolling wheel to the other end of the second mounting plate. This allows the generator to continuously generate electricity during the movement of the gantry crane, ensuring the normal operation of the controller and encoder. There is no need to set up a long power supply cable, and it will not obstruct the movement of the gantry crane positioning equipment.

[0079] This invention also provides a gantry crane positioning method, applied to the controller in a gantry crane positioning device. See [link to related documentation] Figure 6 The gantry crane method includes:

[0080] Step 601: Obtain the pulse direction of the pulses sent by the encoder and accumulate the number of pulses corresponding to each pulse direction.

[0081] For ease of understanding, the working principle of the encoder is briefly described here. The encoder has a built-in grating plate, which rotates coaxially with the encoder's rotating shaft. During the encoder's rotation, the internal grating plate rotates synchronously and outputs multiple sets of pulse signals in real time. Each set of pulse signals contains three sets of square pulse waves. The phase difference between the first and second square pulse waves is 90 degrees. The third square pulse wave is used for reference positioning. Using the third square pulse wave as a reference, the rotation direction of the encoder can be determined by detecting the phase relationship between the first and second square pulse waves, thereby determining the movement direction of the gantry crane.

[0082] Step 602: Determine the moving direction of the gantry crane based on the pulse direction, and determine the moving distance of the gantry crane in each moving direction based on the number of pulses corresponding to each pulse direction.

[0083] It is understandable that there is a correspondence between the encoder's rotation direction and the gantry crane's movement direction. The encoder's rotation direction can be determined by the phase sequence between the first and second square pulse waves in each set of pulse signals, and thus the gantry crane's movement direction. The gantry crane's movement direction essentially refers to the direction of movement of its motion mechanism.

[0084] Accordingly, the distance traveled in each direction can be determined based on the number of pulses corresponding to each direction of movement.

[0085] In some embodiments, the motion mechanism includes: a trolley or an overhead crane;

[0086] The above-mentioned determination of the gantry crane's travel distance in each direction based on the number of pulses corresponding to each pulse direction may include:

[0087] When the gantry crane positioning equipment is connected to the gantry crane's trolley or overhead crane, according to... Calculate the distance the gantry crane travels in each direction.

[0088] Where l represents the distance the gantry crane travels in the current direction, C1 represents the circumference of the first rolling wheel, N represents the number of pulses output by the encoder per revolution, and P represents the number of pulses corresponding to the current pulse direction.

[0089] In other words, the distance the lifted load moves along the X-axis and the distance it moves along the Y-axis can be based on... Calculated.

[0090] In other embodiments, the motion mechanism includes a wire rope reel;

[0091] The above determination of the gantry crane's travel distance in each direction based on the number of pulses corresponding to each pulse direction includes:

[0092] When the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel is not using a movable pulley, according to Calculate the distance the gantry crane travels in each direction.

[0093] Where l represents the distance the gantry crane travels in the current direction, C3 represents the circumference of the shaft of the wire rope reel, P represents the number of pulses corresponding to the current pulse direction, C2 represents the circumference of the friction disc at any end of the wire rope reel, C1 represents the circumference of the first rolling wheel, and N represents the number of pulses output by the encoder for each revolution.

[0094] Alternatively, when the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel uses a set of M movable pulleys, according to... Calculate the distance the gantry crane travels in each direction.

[0095] In other words, when the wire rope reel of the gantry crane is not equipped with a movable pulley, based on Calculate the distance the lifted load travels along the Z-axis. When the gantry crane's wire rope reel is equipped with a movable pulley, based on... Calculate the distance the lifted load moves along the Z-axis.

[0096] Step 603: Determine the position information of the lifted load based on the moving distance of the gantry crane in each direction of movement.

[0097] In this embodiment of the invention, the position information can be coordinate information. This embodiment establishes a spatial coordinate system based on the gantry crane equipment to determine the spatial coordinates of the lifted load, thereby accurately describing the position information of the lifted load. Each coordinate axis has two directions of movement. Based on a preset coordinate zero point, by calculating the movement distance of the gantry crane in each direction on the current coordinate axis, the coordinate value of the gantry crane on the current coordinate axis can be determined, thus clarifying the position information of the lifted load.

[0098] In some embodiments, magnetic devices are provided at a first preset position on the upper surface of the gantry crane track and at a second preset position on the upper surface of the overhead crane moving track, and a sensor is provided at a third preset position on the gantry crane positioning device. Based on this, the method further includes:

[0099] When a sensing signal is received from a sensor, the corresponding pulse count and position information of the sensor are cleared to zero.

[0100] The number of pulses corresponding to the sensor is the same as the number of pulses corresponding to the gantry crane positioning equipment where the sensor is located. The position information corresponding to the sensor is the coordinate value on the coordinate axis of the gantry crane positioning equipment where the sensor is located. For example, the magnetic device can be a magnet. The sensor can be a Hall sensor.

[0101] By setting magnetic devices at the first and second preset positions and a sensor at the third preset position on the gantry crane positioning device, the sensor in the gantry crane positioning device sends a sensing signal when it passes the first or second preset position. When the controller receives the sensing signal, it resets the accumulated number of pulses in each pulse direction to zero and resets the coordinate value of the corresponding coordinate axis to zero. It then restarts the accumulation of pulse counts in different pulse directions for calculating coordinate values. Essentially, this embodiment of the invention is equivalent to defining the first preset position on the upper surface of the gantry crane track as the zero point of the X-axis coordinate, and the second preset position on the upper surface of the crane moving track as the zero point of the Y-axis coordinate. When the gantry crane positioning device passes the zero point, it resets the number of pulses and coordinate values ​​to achieve a reset correction, thereby avoiding accumulated errors caused by long-term use and improving positioning accuracy.

[0102] In some embodiments, the location information includes the lifting height. The lifting height essentially refers to the coordinate value on the Z-axis. The method further includes:

[0103] When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook is obtained;

[0104] Based on the lifting weight, determine the height information of the lifted object;

[0105] Based on the height information, update the lifting height of the suspended load and reset the pulse count corresponding to the wire rope reel to zero.

[0106] There are fixed moving tracks in the X and Y axes. Therefore, in this embodiment of the invention, any preset position on the track can be determined as the coordinate zero point, thereby resetting and correcting the coordinate values ​​on the X and Y axes. However, the gantry crane moves its hook up and down by rotating the wire rope reel; that is, there is no fixed coordinate zero point on the Z axis. Therefore, in this embodiment of the invention, when the hook changes from a suspended state to a lifting state, the lifting weight of the hook, i.e., the weight of the lifted object, is obtained. Based on the weight of the lifted object, the height information of the lifted object can be determined by querying a first preset table. This first preset table contains the weight and corresponding height information for each lifted object.

[0107] The height of the lifted object is the Z-axis coordinate value corresponding to the change from a suspended state to a lifted state. Using this height information, the lifting height of the object, i.e., the Z-axis coordinate value, can be updated and corrected. The pulse count is then reset to zero. Based on the current lifting height, the pulse count in each pulse direction is re-accumulated to determine the direction and distance of movement. Combining the current lifting height with the direction and distance of movement, the real-time height of the lifted object, i.e., the Z-axis coordinate value, is then determined.

[0108] Compared to existing technologies, this invention fixes each gantry crane positioning device to each of the gantry crane's moving mechanisms, allowing each encoder to move synchronously with each moving mechanism and output corresponding pulse signals. Based on these pulse signals, the movement distance of each moving mechanism in different directions is calculated, ultimately determining the coordinates of the lifted load on different coordinate axes, and thus determining the spatial coordinates of the lifted load. This achieves the goal of real-time monitoring of the spatial coordinates of the lifted load.

[0109] Furthermore, by incorporating magnetic devices and sensors, this embodiment of the invention enables the resetting and correction of coordinate values ​​along the X and Y axes; and by using the height information of the suspended load, the resetting and correction of coordinate values ​​along the Z axis can be achieved. By resetting and correcting the coordinate values ​​on each axis, accumulated errors can be effectively reduced, and positioning accuracy improved.

[0110] In other embodiments, the gantry crane positioning device further includes a pressure sensor and a temperature sensor, which are disposed on the hook of the gantry crane; the above method further includes:

[0111] When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook, as well as the current initial air pressure and initial temperature values, are obtained.

[0112] The system acquires real-time air pressure and temperature values ​​during the lifting process, and determines the direction and distance of movement of the lifted load based on these values, as well as the initial air pressure and initial temperature values.

[0113] Based on the lifting weight, determine the initial height of the lifted object, and based on the initial height, direction of movement, and distance of movement, determine the lifting height of the lifted object.

[0114] The X-axis and Y-axis coordinate values ​​are determined by setting values ​​at different locations on the gantry crane. Figure 2 The gantry crane positioning device shown can obtain the coordinate values ​​of the X-axis and Y-axis. For the Z-axis coordinate value, in addition to the method of determining the coordinate value based on pulses using the aforementioned gantry crane positioning device, this embodiment of the invention also provides another gantry crane positioning device for determining the Z-axis coordinate value. This gantry crane positioning device includes a pressure sensor, a temperature sensor, and a controller. Both the pressure sensor and the temperature sensor are mounted on the hook of the gantry crane, and both are communicatively connected to the controller.

[0115] The core of the aforementioned gantry crane positioning equipment lies in utilizing the law of atmospheric pressure variation with altitude to determine the coordinate values ​​on the Z-axis. When the hook changes from a suspended state to a lifted state, the initial air pressure and temperature values ​​can be collected using air pressure and temperature sensors. Based on these initial air pressure and temperature values, the current initial altitude can be calculated. The specific calculation formula is as follows:

[0116]

[0117] Where h represents the current initial altitude, P0 represents the standard atmospheric pressure, which is 101.325 kPa, P represents the current initial air pressure, and T represents the current initial temperature.

[0118] During the lifting process, real-time air pressure and temperature values ​​are collected. Based on these values, the current real-time altitude can be calculated. The difference between the real-time altitude and the initial altitude is then calculated and defined as the altitude difference.

[0119] In this embodiment of the invention, when the hook changes from a suspended state to a lifted state, the lifting weight of the hook, i.e., the weight of the lifted object, is also acquired. As described above, based on the weight of the lifted object, the height information of the lifted object can be determined accordingly. Based on the height information of the lifted object, the height coordinates of the lifted object can be updated and corrected. By superimposing the aforementioned height difference on this height coordinate, the real-time height coordinates of the lifted object can be obtained.

[0120] The controller of this gantry crane positioning device also includes a wireless transceiver unit for transmitting height coordinates to the control center. The device also includes an accelerometer and a battery-powered circuit. The battery-powered circuit supplies power to the sensors and controller. The accelerometer detects whether the hook is stationary. When the hook is stationary, the controller wirelessly transmits the current height coordinates to the control center, significantly reducing power consumption.

[0121] Low-power LoRaWAN technology can be used for wireless transmission. When data transmission is not required, the gantry crane positioning device is in standby mode, which further reduces product power consumption while still meeting the requirements for networking distance and number of networks.

[0122] This invention determines the height coordinates of a lifted load by using a pressure sensor and a temperature sensor. By integrating the sensor and controller into one unit, it features a simplified structure, high measurement accuracy (error ≤30cm), low power consumption, small size, easy installation, and convenient maintenance.

[0123] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0124] The following are device embodiments of the present invention. For details not described in detail, please refer to the corresponding method embodiments described above.

[0125] Figure 7 A schematic diagram of the gantry crane positioning device provided in an embodiment of the present invention is shown. For ease of explanation, only the parts related to the embodiment of the present invention are shown, and are described in detail below:

[0126] like Figure 7 As shown, the gantry crane positioning device 7 includes: an acquisition module 71 and a calculation module 72.

[0127] The acquisition module 71 is used to acquire the pulse direction of the pulses sent by the encoder and accumulate the number of pulses corresponding to each pulse direction.

[0128] The calculation module 72 is used to determine the moving direction of the gantry crane based on the pulse direction, and to determine the moving distance of the gantry crane in each moving direction based on the number of pulses corresponding to each pulse direction.

[0129] The calculation module 72 is also used to determine the position information of the lifted load based on the moving distance of the gantry crane in each moving direction.

[0130] Optionally, the motion mechanism includes a trolley or an overhead crane. The calculation module 72 is specifically used for:

[0131] When the gantry crane positioning equipment is connected to the gantry crane's trolley or overhead crane, according to... Calculate the distance the gantry crane travels in each direction of movement;

[0132] Where l represents the distance the gantry crane travels in the current direction, C1 represents the circumference of the first rolling wheel, N represents the number of pulses output by the encoder per revolution, and P represents the number of pulses corresponding to the current pulse direction.

[0133] Optionally, the motion mechanism includes a wire rope reel. The calculation module 72 is specifically used for:

[0134] When the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel is not using a movable pulley, according to Calculate the distance the gantry crane travels in each direction of movement;

[0135] Where l represents the distance the gantry crane moves in the current direction, C3 represents the circumference of the shaft of the wire rope reel, P represents the number of pulses corresponding to the current pulse direction, C2 represents the circumference of the friction disc at any end of the wire rope reel, C1 represents the circumference of the first rolling wheel, and N represents the number of pulses output by the encoder for each revolution.

[0136] Alternatively, when the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel uses a set of M movable pulleys, according to... Calculate the distance the gantry crane travels in each direction.

[0137] Optionally, magnetic devices are installed at a first preset position on the upper surface of the gantry crane track and at a second preset position on the upper surface of the overhead crane moving track, and a sensor is installed at a third preset position on the gantry crane positioning device. The calculation module 72 is also used for:

[0138] When a sensing signal is received from a sensor, the corresponding pulse count and position information of the sensor are cleared to zero.

[0139] Optionally, the location information includes the lifting height. The calculation module 72 is also used for:

[0140] When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook is obtained;

[0141] Determine the height information of the suspended object based on the lifting weight;

[0142] Based on the height information, update the lifting height of the suspended load and reset the pulse count corresponding to the wire rope reel to zero.

[0143] Optionally, the gantry crane positioning device also includes a pressure sensor and a temperature sensor, which are mounted on the hook of the gantry crane; the calculation module 72 is also used for:

[0144] When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook, as well as the current initial air pressure and initial temperature values, are obtained.

[0145] The system acquires real-time air pressure and temperature values ​​during the lifting process, and determines the direction and distance of movement of the lifted load based on these values, as well as the initial air pressure and initial temperature values.

[0146] Based on the lifting weight, determine the height information of the lifted object, and based on the height information, the direction of movement, and the distance of movement, determine the lifting height of the lifted object.

[0147] In this embodiment of the invention, each positioning device of the gantry crane is fixedly connected to each moving mechanism of the gantry crane, thereby enabling each encoder to move synchronously with each moving mechanism and output corresponding pulse signals. The calculation module 71 calculates the moving distance of each moving mechanism in different directions based on the pulse signals, ultimately determining the position information of the lifted load. This achieves the purpose of real-time monitoring of the position information of the lifted load.

[0148] Furthermore, by incorporating magnetic devices and sensors, this embodiment of the invention enables the resetting and correction of coordinate values ​​along the X and Y axes; and by using the height information of the suspended load, it enables the resetting and correction of coordinate values ​​along the Z axis. The calculation module 72 effectively reduces accumulated errors and improves positioning accuracy by resetting and correcting coordinate values ​​on each axis.

[0149] Figure 8 This is a schematic diagram of the controller provided in an embodiment of the present invention. Figure 8 As shown, the controller 8 in this embodiment includes a processor 80, a memory 81, and a computer program 82 stored in the memory 81 and executable on the processor 80. When the processor 80 executes the computer program 82, it implements the steps in the various gantry crane positioning method embodiments described above, for example... Figure 6 Steps 601 to 603 are shown. Alternatively, when the processor 80 executes the computer program 82, it implements the functions of each module / unit in the above-described device embodiments, for example... Figure 7 The functions of modules 71 to 72 are shown.

[0150] For example, the computer program 82 can be divided into one or more modules / units, which are stored in the memory 81 and executed by the processor 80 to complete the present invention. The one or more modules / units can be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 82 in the controller 8. For example, the computer program 82 can be divided into... Figure 7 Modules 71 to 72 are shown.

[0151] The controller 8 can be a computing device such as a desktop computer, laptop, handheld computer, or cloud server. The controller 8 may include, but is not limited to, a processor 80 and a memory 81. Those skilled in the art will understand that... Figure 8 This is merely an example of controller 8 and does not constitute a limitation on controller 8. It may include more or fewer components than shown, or combine certain components, or different components. For example, the controller may also include input / output devices, network access devices, buses, etc.

[0152] The processor 80 may be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor may be a microprocessor or any conventional processor.

[0153] The memory 81 can be an internal storage unit of the controller 8, such as a hard disk or memory of the controller 8. The memory 81 can also be an external storage device of the controller 8, such as a plug-in hard disk, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card equipped on the controller 8. Furthermore, the memory 81 can include both internal storage units and external storage devices of the controller 8. The memory 81 is used to store the computer program and other programs and data required by the controller. The memory 81 can also be used to temporarily store data that has been output or will be output.

[0154] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0155] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0156] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0157] In the embodiments provided by this invention, it should be understood that the disclosed devices / controllers and methods can be implemented in other ways. For example, the device / controller embodiments described above are merely illustrative. For instance, the division of modules or units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.

[0158] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0159] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0160] If the integrated module / unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the above embodiments of the present invention can also be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various gantry crane positioning method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include: any entity or device capable of carrying the computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, etc. The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A method for positioning a gantry crane, characterized in that, A controller is used in a gantry crane positioning device, wherein the gantry crane positioning device further includes an encoder and a mounting mechanism, the encoder is connected to the motion mechanism of the gantry crane via the mounting mechanism, and the encoder moves synchronously with the motion mechanism; The method includes: Obtain the pulse direction of the pulses sent by the encoder, and accumulate the number of pulses corresponding to each pulse direction; Based on the pulse direction, the moving direction of the gantry crane is determined, and based on the number of pulses corresponding to each pulse direction, the moving distance of the gantry crane in each moving direction is determined; Based on the moving distance of the gantry crane in each direction of movement, the position information of the lifted load is determined; The motion mechanism includes a wire rope reel; Based on the number of pulses corresponding to each pulse direction, the traveling distance of the gantry crane in each moving direction is determined, including: When the gantry crane positioning device is connected to the gantry crane's wire rope reel, and the wire rope reel is not using a movable pulley, according to Calculate the distance the gantry crane travels in each direction of movement; in, This indicates the distance the gantry crane has traveled in the current direction of movement. This indicates the circumference at the shaft of the wire rope reel. This indicates the number of pulses corresponding to the current pulse direction. This represents the circumference of the friction disk located at either end of the wire rope reel. This indicates the circumference of the first rolling wheel. This indicates the number of pulses output by the encoder per revolution. The location information includes the lifting height, and the method further includes: When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook is obtained; Based on the lifting weight, determine the height information of the lifted object; Based on the height information, the lifting height of the suspended object is updated, and the pulse count corresponding to the wire rope reel is cleared to zero.

2. The gantry crane positioning method according to claim 1, characterized in that, The motion mechanism includes: a trolley or an overhead crane; Based on the number of pulses corresponding to each pulse direction, the traveling distance of the gantry crane in each moving direction is determined, including: When the gantry crane positioning device is connected to the gantry crane's trolley or overhead crane, according to Calculate the distance the gantry crane travels in each direction of movement; in, This indicates the distance the gantry crane has traveled in the current direction of movement. This indicates the circumference of the first rolling wheel. This indicates the number of pulses output by the encoder per revolution. This indicates the number of pulses corresponding to the current pulse direction.

3. The gantry crane positioning method according to claim 2, characterized in that, Magnetic devices are installed at the first preset position on the upper surface of the gantry crane track and at the second preset position on the upper surface of the overhead crane moving track, and a sensor is installed at the third preset position on the gantry crane positioning device. The method further includes: When a sensing signal is received from the sensor, the pulse count and position information corresponding to the sensor are cleared to zero.

4. The gantry crane positioning method according to any one of claims 1-3, characterized in that, The mounting mechanism includes a bracket, a first mounting plate, a first rolling wheel, and a first pressure spring; The first end of the bracket is used to fix and connect the motion mechanism of the gantry crane, and the second end of the bracket is perpendicularly connected to one end of the first mounting plate; The other end of the first mounting plate is provided with a first through hole, the encoder and the first rolling wheel are respectively disposed on both sides of the other end of the first mounting plate, and the rotating shaft of the encoder is fixedly connected to the center position of the first rolling wheel through the first through hole; The two ends of the first pressure spring are respectively connected to the second end of the bracket and the other end of the first mounting plate to adjust the tilt angle of the first mounting plate so that the first rolling wheel rubs and rolls along the rolling surface.

5. The gantry crane positioning method according to claim 1, characterized in that, The gantry crane positioning device further includes a pressure sensor and a temperature sensor, which are mounted on the hook of the gantry crane; the method further includes: When the hook of the gantry crane changes from a suspended state to a lifting state, the lifting weight of the hook, as well as the current initial air pressure and initial temperature values, are obtained. Real-time air pressure and temperature values ​​are acquired during the lifting process, and the direction and distance of movement of the lifted load are determined based on the real-time air pressure, real-time temperature, initial air pressure, and initial temperature values. Based on the lifting weight, the height information of the lifted object is determined, and based on the height information, the direction of movement, and the distance of movement, the lifting height of the lifted object is determined.

6. A gantry crane positioning device, characterized in that, The device is applied to the gantry crane positioning method according to any one of claims 1-5; the device includes: an encoder, a mounting mechanism, and a controller; The encoder is connected to the motion mechanism of the gantry crane via the mounting mechanism, and the encoder moves synchronously with the motion mechanism. The controller is electrically connected to the encoder and is used to acquire the pulse direction of the pulses sent by the encoder and accumulate the number of pulses corresponding to each pulse direction; based on the pulse direction, the controller determines the moving direction of the gantry crane and, based on the number of pulses corresponding to each pulse direction, determines the moving distance of the gantry crane in each moving direction; based on the moving distance of the gantry crane in each moving direction, the controller determines the position information of the lifted load.

7. The gantry crane positioning device according to claim 6, characterized in that, The mounting mechanism includes a bracket, a first mounting plate, a first rolling wheel, and a first pressure spring; The first end of the bracket is used to fix and connect the motion mechanism of the gantry crane, and the second end of the bracket is perpendicularly connected to one end of the first mounting plate; The other end of the first mounting plate is provided with a first through hole, the encoder and the first rolling wheel are respectively disposed on both sides of the other end of the first mounting plate, and the rotating shaft of the encoder is fixedly connected to the center position of the first rolling wheel through the first through hole; The two ends of the first pressure spring are respectively connected to the second end of the bracket and the other end of the first mounting plate to adjust the tilt angle of the first mounting plate so that the first rolling wheel rubs and rolls along the rolling surface.

8. The gantry crane positioning device according to claim 7, characterized in that, Also includes: The second mounting plate, generator, second rolling wheel, second pressure spring, and energy storage device; One end of the second mounting plate is vertically connected to the third end of the bracket, and the other end of the second mounting plate is provided with a second through hole; The generator and the second rolling wheel are respectively disposed on both sides of the other end of the second mounting plate, and the rotating shaft of the generator is fixedly connected to the center position of the second rolling wheel through the second through hole; The two ends of the second pressure spring are respectively connected to the third end of the bracket and the other end of the second mounting plate to adjust the tilt angle of the second mounting plate so that the second rolling wheel rubs and rolls along the rolling surface; The energy storage device is electrically connected to both the generator and the controller.

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