Intelligent control system and intelligent control method of bridge girder erection machine

Abstract

The invention provides an intelligent control system and an intelligent control method of a bridge girder erection machine, and relates to the technical field of bridge construction application, the intelligent system comprises a plurality of variable frequency controllers which are respectively installed on a front support and a middle support, a front crown block and a rear crown block, and a rear support, the variable frequency controller controls the rotating speed of the transverse moving motors of the front support and the rear support, the rotating speed of the walking motors of the front crown block and the rear crown block and the rotating speed of the front and rear running motors of the middle support and the rear support according to a control instruction of the PLC control system. The rotating speed of the motor is controlled through the frequency converter, so that the left-right moving synchronism of the front support and the middle support of the bridge girder erection machine is effectively controlled, the walking synchronism of the front crown block and the rear crown block on the left and right wheels on the track is effectively controlled, and derailment caused by inconsistent speeds of the wheels on the two sides of the track is avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge construction applications, and in particular to an intelligent control system and an intelligent control method for a bridge erecting machine. Background Art

[0002] A bridge erecting machine is a type of equipment commonly used for erecting and dismantling beams in bridge construction. It is an integral large-span bridge construction equipment that minimizes manpower construction. Bridge erecting machines can be divided into: single-beam bridge erecting machines, double-cantilever bridge erecting machines, and double-beam bridge erecting machines.

[0003] Traditional bridge-building machine control uses contactor control, which has complex circuits, difficult maintenance, unstable control and other problems. It is easy for the motor to be out of sync. In the absence of synchronization, the wheels are prone to derailment, and there is a risk of the bridge-building machine tipping over due to eccentric loading. Summary of the invention

[0004] In view of this, the present invention provides an intelligent control system and an intelligent control method for a bridge erecting machine, which at least partially solve the problems existing in the prior art.

[0005] To achieve the above-mentioned object, in a first aspect, the present invention provides an intelligent control system for a bridge erecting machine, the intelligent control system comprising: a front support, a middle support, a rear support, a main beam, a front support track, a middle support track, a front locking door, a rear locking door, a front crane, a rear crane and a rear support; The front support and the rear support are used to support the main beam; The front crane and the rear crane are arranged on the crane track on the main beam, and move forward and backward on the main beam along the crane track; The front locking door and the rear locking door are arranged at two ends of the main beam and are used to connect the main beam; The front branch is arranged on the front branch track and moves left and right along the front branch track; The middle support and the rear support are arranged below the main beam, and are used to support the main beam so that the main beam can move back and forth along the span direction; The middle branch is arranged on the middle branch track and moves left and right along the middle branch track; The intelligent control system also includes: a PLC control system and a plurality of frequency conversion controllers; The multiple frequency conversion controllers are respectively installed on the front support, the middle support, the front crane, the rear crane and the rear support. The frequency conversion controllers are used to control the rotation speed of the transverse motor of the front support and the rear support, the rotation speed of the travel motor of the front crane and the rear crane, and the rotation speed of the front and rear running motors of the middle branch and the rear support according to the control instructions of the PLC control system, so that the operation of the transverse motor of the front support and the middle branch is synchronized, the operation of the travel motor of the front crane and the rear crane is synchronized, and the operation of the front and rear running motors of the middle branch and the rear support is synchronized.

[0006] In some possible implementations, the intelligent control system further includes: A plurality of heavy load sensors are respectively arranged at the flange connection of the front support, the leg connection of the middle support and the connection of the rear support, and are used to monitor the load data of the points where the front support, the middle support and the rear support contact the main beam; and transmit the load data to the PLC control system; The PLC control system is used to compare the load data of each point with the preset dangerous load value of each point. When the load data reaches the dangerous load value corresponding to each point, an alarm is issued or the operation of the bridge-building machine is stopped, and the front support, the middle support and the rear support are automatically adjusted to run to the positions corresponding to the safe load values.

[0007] In some possible implementations, the intelligent control system further includes: A first tilt sensor, installed on the front locking door and the rear locking door respectively, is used to monitor first tilt angle data of two points in front and behind the main beam, and transmit the first tilt angle data to the PLC control system; The PLC control system is used to compare the first inclination angle data with a preset first dangerous inclination value. When the first inclination angle data reaches the corresponding first dangerous inclination value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the front crane and the rear crane are automatically adjusted to run to the position of the first safe inclination value.

[0008] In some possible implementations, the intelligent control system further includes: Second inclination sensors are respectively arranged on the steel wire ropes of the front crane and the rear crane, and are used to monitor second inclination angle data of the steel wire ropes and transmit the second inclination angle data to the PLC control system; The PLC control system is used to compare the second inclination angle data with a preset second dangerous inclination value. When the second inclination angle data reaches the corresponding second dangerous inclination value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the front crane and the rear crane are automatically adjusted to run to the position of the second safe inclination value.

[0009] In some possible implementations, the intelligent control system further includes: A plurality of displacement sensors are respectively arranged on the front branch track, the middle branch track and the overhead crane track, and are used to monitor the first travel displacement data of the wheel box of the front branch relative to the front branch track, the second travel displacement data of the wheel box of the middle branch relative to the middle branch track, and the third travel displacement data of the wheel boxes of the front overhead crane and the rear overhead crane relative to the overhead crane track, and transmit the first travel displacement data, the second travel displacement data and the third travel displacement data to the PLC control system respectively; The PLC control system is used to compare the first walking displacement data, the second walking displacement data and the third walking displacement data with the preset first dangerous displacement value, the second dangerous displacement value and the third dangerous displacement value respectively, and when the first walking displacement data reaches the first dangerous displacement value, and / or when the second walking displacement data reaches the second dangerous displacement value, and / or when the third walking displacement data reaches the third dangerous displacement value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the front support, the middle support, the front crane and the rear crane are automatically adjusted to run to the preset first safe displacement value, the second safe displacement value and the third safe displacement value respectively.

[0010] In some possible implementations, a visual 3D camera is installed on the front crane and the rear crane respectively, for monitoring the size parameters of the bridge and transmitting the size values ​​to the PLC control system; The PLC control system is used to calculate the target positions of the front crane and the rear crane from the two ends of the main beam according to the size parameters of the bridge. When the front crane and the rear crane move to the target positions, the hoisting equipment is lowered to start the automatic beam hoisting mode.

[0011] In some possible implementations, the intelligent control system further includes: A laser rangefinder, arranged at the intersection of the main beam and the wheel box of the middle branch, for real-time monitoring of the distance between the extended end of the main beam and the middle branch, and transmitting the distance to the PLC control system; The PLC control system is used to compare the distance with a preset danger distance value. When the distance reaches the preset danger distance value, an alarm is issued or the operation of the bridge erection machine is stopped, and the distance between the extended end of the main beam and the middle branch is automatically adjusted to a preset safety distance value.

[0012] In some possible implementations, the intelligent control system further includes: A human-computer interaction interface is used to set the control data parameters of the bridge-building machine, and the control data parameters include but are not limited to a dangerous load value, a safe load value, a first dangerous inclination value, a first safe inclination value, a second dangerous inclination value, a second safe inclination value, a first dangerous displacement value, a second dangerous displacement value, a third dangerous displacement value, a first safe displacement value, a second safe displacement value, a third safe displacement value, a dangerous distance value, and a safe distance value.

[0013] In some possible implementations, the intelligent control system further includes: A plurality of slave stations and wireless bridges, the PLC control system controls the plurality of slave stations through the wireless bridges, the PLC control system obtains data collected by sensors corresponding to different components of the bridge-building machine through the plurality of slave stations, and controls the limiters through the corresponding slave stations according to the sensor data to limit the various components of the bridge-building machine.

[0014] In a second aspect, the present invention further provides an intelligent control method for a bridge erecting machine, the intelligent control method being applied to the intelligent control system of the bridge erecting machine described in the first aspect, the intelligent control method comprising: The frequency conversion controllers installed on the front branch and the rear branch control the rotation speeds of the traverse motors of the front branch and the middle branch on the front branch track and the middle branch track according to the control instructions of the PLC control system, so that the traverse motors of the front branch and the middle branch operate synchronously; The frequency conversion controller installed on the front crane and the rear crane controls the rotation speed of the travel motors of the front crane and the rear crane on the crane track on the main beam according to the control instruction of the PLC control system, so that the travel motors of the front crane and the rear crane run synchronously; The frequency conversion controller installed on the middle branch and the rear support controls the rotation speed of the front and rear running motors of the middle branch and the rear support according to the control instructions of the PLC control system, so that the front and rear running motors of the middle branch and the rear support run synchronously.

[0015] The beneficial effects of the embodiments of the present invention are as follows: The present invention provides an intelligent control system for a bridge erecting machine, comprising a plurality of frequency conversion controllers, which are respectively installed on the front support and the middle support, the front crane and the rear crane, and the rear support. The frequency conversion controller controls the rotation speed of the traverse motor of the front support and the rear support, the rotation speed of the travel motor of the front crane and the rear crane, and the rotation speed of the front and rear running motors of the middle support and the rear support according to the control instructions of the PLC control system. The present invention controls the motor speed through the frequency converter so that the synchronization of the left and right movement of the front and middle branches of the bridge erecting machine is effectively controlled, and the synchronization of the left and right wheels of the front crane and the rear crane on the track is effectively controlled, so as to avoid derailment caused by inconsistent wheel speeds on both sides of the track. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] Figure 1 It is a side view of the overall structure of a bridge erecting machine according to an embodiment of the present invention; Figure 2 It is a framework diagram of an intelligent control system of a bridge erecting machine according to an embodiment of the present invention; Figure 3 The invention discloses an intelligent control method for a bridge erecting machine according to an embodiment of the present invention.

[0018] Description of Figure Numbers: 1. Front support; 2. Middle support; 3. Rear support; 4. Main beam; 5. Front support track; 6. Middle support track; 7. Front locking door; 8. Rear locking door; 9. Front crane; 10. Rear crane; 11. Rear support; 12. Crane track. DETAILED DESCRIPTION

[0019] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0020] It should be noted that the following embodiments and features in the embodiments may be combined with each other in the absence of conflict; and, based on the embodiments in the present disclosure, all other embodiments obtained by ordinary technicians in the field without making any creative work are within the scope of protection of the present disclosure.

[0021] It should be noted that various aspects of the embodiments within the scope of the appended claims are described below. It should be apparent that the aspects described herein may be embodied in a wide variety of forms, and any specific structure and / or function described herein is merely illustrative. Based on the present disclosure, it should be understood by those skilled in the art that an aspect described herein may be implemented independently of any other aspect, and two or more of these aspects may be combined in various ways. For example, any number of aspects described herein may be used to implement the device and / or practice the method. In addition, other structures and / or functionalities other than one or more of the aspects described herein may be used to implement this device and / or practice this method.

[0022] The intelligent control system of the bridge erecting machine provided by the embodiment of the present invention adopts a PLC control system, and is equipped with a 4G module with a remote monitoring operation function. The wireless transmission control reduces the wiring at the construction site, and the heavy-duty sensor, displacement sensor, tilt sensor and other limiters are used together to increase the safety and reliability of the operation. The motor speed is controlled by a frequency converter to ensure the synchronization of the motor. The intelligent control system of the bridge erecting machine in the embodiment of the present invention adopts a human-machine interface control, and is equipped with a visual interface system. The computer automatically calculates the three-dimensional size parameters of the beam and combines the PLC control to realize the intelligent control of the bridge erecting machine. Compared with the traditional model of bridge erecting machine control, it can operate the bridge erecting machine more intelligently, safely, stably and reliably, and has reliable quality, convenient use, and a higher safety factor, which is conducive to solving the safety hazards caused by the traditional bridge erecting machine control system.

[0023] Figure 1 1 is a side view of the overall structure of a bridge erecting machine according to an embodiment of the present invention, as shown in FIG. Figure 1As shown, it includes: a front support 1, a middle support 2, a rear support 3, a main beam 4, a front support track 5, a middle support track 6, a front lock door 7, a rear lock door 8, a front overhead car 9, a rear overhead car 10 and a rear support 11; the front support 1 and the rear support 3 are configured to support the two main beams 4; the front overhead car 9 and the rear overhead car 10 are arranged on the overhead car track 12 on the two main beams 4, and move forward and backward along the overhead car track 12 between the two main beams 4; the front door lock and the rear door lock are arranged at both ends of the two main beams 4 for connecting the two main beams 4; the front support 1 is arranged on the front support track 5, and can move left and right along the front support track 5; the middle support 2 and the rear support 11 are arranged on the two main beams 4 is used to support the two main beams 4 below so that the two main beams 4 can move along the span direction; the middle branch 2 is set on the middle branch track 6 and moves left and right along the track; it also includes a PLC control system and multiple frequency conversion controllers, wherein the multiple frequency conversion controllers are respectively installed on the front support 1 and the rear support 3, the front crane 9 and the rear crane 10, and the middle branch 2 and the rear support 11, and are respectively used to control the speed of the transverse motor of the front support 1 and the rear support 3, the speed of the travel motor of the front crane 9 and the rear crane 10, and the speed of the front and rear running motors of the middle branch 2 and the rear support 11 according to the control instructions of the PLC control system.

[0024] Specifically, in the present embodiment, the front support 1 and the middle support 2 traverse motors respectively use frequency converters to control the speed of the motors to realize synchronous operation, and the data is transmitted to the PLC control system. When the situation is not synchronized, the intelligent control system will issue a control instruction through the PLC control system, and the frequency conversion controller controls the motor speed according to the control instruction to prevent the front support 1 and the middle support 2 from causing derailment when the speed of the traverse motor is not synchronized, and the action of each motor can also be controlled separately. Similarly, the front day car 9 and the rear day car 10 walking motors respectively use frequency converters to control the speed of the motors to realize synchronous operation, that is, when the situation is not synchronized, the intelligent control system will issue a control instruction through the PLC control system, and the frequency conversion controller controls the motor speed according to the control instruction to prevent the front day car 9 and the rear day car 10 wheels from walking on the track not synchronously and causing derailment. The speed of the motors of the middle support 2 and the rear support 11 is controlled by the same method to prevent the main beam 4 from moving at different distances on both sides and causing deviation, and of course, the action of each motor can also be controlled separately.

[0025] Taking the movement of the front crane 9 and the rear crane 10 as an example, the wheels on both sides of the front crane 9 move at different speeds, which will cause the wheels to deviate from the track. The intelligent control system will automatically detect the walking speed of the wheels on both sides, and the problem can be solved by outputting a signal to the frequency converter to control the motor speed through the computer operation of the PLC control system so that the wheels move synchronously. The embodiment of the present invention controls the motor speed through the frequency converter so that the synchronization of the left and right movement of the front support 1 and the middle support 2 of the bridge erection machine is effectively controlled, and the synchronization of the left and right wheels of the front crane 9 and the rear crane 10 on the crane track 12 is effectively controlled.

[0026] In some embodiments, the intelligent control system also includes: multiple displacement sensors, which are respectively arranged on the front branch track 5, the middle branch track 6 and the overhead crane track 12, and are used to monitor the first travel displacement data of the wheel box of the front branch 1 relative to the front branch track 5, the second travel displacement data of the wheel box of the middle branch 2 relative to the middle branch track 6, and the third travel displacement data of the wheel boxes of the front overhead crane 9 and the rear overhead crane 10 relative to the overhead crane track 12, and transmit the first travel displacement data, the second travel displacement data and the third travel displacement data to the PLC control system respectively; the PLC control system is used to compare the first travel displacement data, the second travel displacement data and the third travel displacement data with the preset first dangerous displacement value, the second dangerous displacement value and the third dangerous displacement value respectively, and when the first travel displacement data reaches the first dangerous displacement value, and / or when the second travel displacement data reaches the second dangerous displacement value, and / or when the third travel displacement data reaches the third dangerous displacement value, an alarm is issued or the bridge erection machine is stopped, and the front branch 1, the middle branch 2, the front overhead crane 9 and the rear overhead crane 10 are automatically adjusted to run to the preset first safe displacement value, the second safe displacement value and the third safe displacement value respectively.

[0027] In this embodiment, the travel distance of each wheel box on its own track can be monitored in real time through the displacement sensor, and the data can be transmitted to the PLC control system. When a dangerous value appears, an alarm will be immediately issued or the operation of the bridge crane will be stopped, and then the corresponding mechanisms (such as the front support 1, the middle support 2, the front crane 9 and the rear crane 10) will be automatically adjusted to run to a safe position.

[0028] In some embodiments, the intelligent control system also includes: multiple heavy-load sensors, which are respectively arranged at the flange connection of the front support 1, the leg connection of the middle support 2 and the connection of the rear support 11, and are used to monitor the load data of the points where the front support 1, the middle support 2 and the rear support 11 contact the main beam 4; and transmit the load data to the PLC control system; the PLC control system is used to compare the load data of each point with the preset dangerous load value of each point. When the load data reaches the dangerous load value corresponding to each point, an alarm is issued or the operation of the bridge erection machine is stopped, and the front support 1, the middle support 2 and the rear support 11 are automatically adjusted to run to the positions corresponding to the safe load values.

[0029] In some embodiments, the intelligent control system also includes: a first tilt sensor, respectively installed on the front locking door 7 and the rear locking door 8, for monitoring the first tilt angle data of the two points in front and behind the main beam 4, and transmitting the first tilt angle data to the PLC control system; the PLC control system is used to compare the first tilt angle data with the preset first dangerous tilt value. When the first tilt angle data reaches the corresponding first dangerous tilt value, an alarm is issued or the bridge erection machine is stopped, and the front crane 9 and the rear crane 10 are automatically adjusted to run to the position of the first safe tilt value.

[0030] Specifically, the tilt sensor installed on the front lock door 7 will display the angle of the main beam 4 tilting forward, and a first dangerous tilt value is set in advance inside the intelligent control system, that is, this first dangerous tilt value is the maximum tilt value allowed for the main beam 4 to tilt. When the tilt angle data exceeds the set maximum tilt angle value, the computer of the PLC control system performs calculations. When the first tilt angle data exceeds the maximum allowable tilt angle value, an alarm will be issued and the bridge erection machine will be controlled to forcibly stop running, and the bridge erection machine components will be automatically controlled to run in the opposite direction to the appropriate position. On the contrary, the backward tilt of the main beam 4 is similarly controlled by the tilt sensor installed on the rear lock door 8. In this embodiment, the tilt sensors of the front lock door 7 and the rear lock door 8 can effectively control the angle of the main beam 4 tilting forward or backward.

[0031] In this embodiment, the displacement sensors installed on the front branch track 5, the middle branch track 6 and one side of the overhead crane track 12 are used to monitor the displacement of the wheel boxes on each track to the left and right. The heavy load sensors installed on each fulcrum monitor the heavy load on the left and right of the bridge erecting machine. The tilt sensors installed on the main beam 4, the front locking door 7 and the rear locking door 8 monitor the tilt angles of the main beam 4 front, back, left and right. The comprehensive processing of the data fed back by these three groups of conditions can realize the effective monitoring and control of the overload of the bridge erecting machine.

[0032] Taking the overall leftward load of the center of gravity of the bridge erection machine as an example, two displacement points are set on the front support track 5, the middle support track 6, and the overhead crane track 12. The values ​​are set in advance in the intelligent control system. The first displacement point is the overload alarm point, and the second point is the forced stop point. When each component moves to the left to the first displacement point, the PLC operation issues a command alarm light to remind that there is a risk of overload. At the same time, the overload sensor at each support point displays the overload data. The intelligent control system has set the maximum allowable value in advance through the touch screen. If the overload weight is within the allowable range, the intelligent control system of the bridge erection machine can continue to control the bridge erection machine components to move to the left and monitor the bridge erection machine status at all times; if the overload weight is greater than or equal to the set allowable value, the program controls the bridge erection machine to stop forcibly, and then the intelligent control system of the bridge erection machine automatically controls the bridge erection machine components to move to the right to the appropriate position. After passing the first point, when reaching the second set point displacement value, this point is closest to the set maximum overload weight value. At this time, the bridge erection machine stops running forcibly, and then the bridge erection machine control system automatically controls the bridge erection machine components to move to the right to the appropriate position. The control principle of rightward load is the same.

[0033] In some embodiments, the intelligent control system may also include: a second inclination sensor, which is respectively arranged on the steel wire ropes of the front crane 9 and the rear crane 10, for monitoring the second inclination angle data of the steel wire ropes and transmitting the second inclination angle data to the PLC control system; the PLC control system is used to compare the second inclination angle data with the preset second dangerous inclination value. When the second inclination angle data reaches the corresponding second dangerous inclination value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the front crane 9 and the rear crane 10 are automatically adjusted to run to the position of the second safe inclination value.

[0034] Specifically, during the process of lifting the beam, when the steel wire rope on one side tilts forward, the tilt sensor vertically fixed on a fixed steel wire rope will display the forward tilt angle, and a maximum tilt angle value is set in advance inside the intelligent control system. The calculation is performed through the PLC control system. When the tilt angle exceeds the set value, an alarm is issued and the bridge erection machine is forced to stop running, and the bridge erection machine parts are automatically controlled to run in the opposite direction to the appropriate position. The backward tilt of the steel wire rope is controlled in the same way. In this embodiment, the tilt sensor fixed on a steel wire fixed by a pulley can effectively monitor the tilt angle of the steel wire rope.

[0035] In some embodiments, a visual 3D camera is installed on the front crane 9 and the rear crane 10, respectively, for monitoring the dimensional parameters of the bridge and transmitting the dimensional values ​​to the PLC control system; the PLC control system is used to calculate the target positions of the front crane 9 and the rear crane 10 at both ends of the main beam 4 according to the dimensional parameters of the bridge. When the front crane 9 and the rear crane 10 move to the target positions, the hoisting equipment is lowered to start the automatic beam lifting mode.

[0036] Specifically, after the bridge is transported to the bottom of the bridge erecting machine, a visual 3D camera installed on each of the front trolley 9 and the rear trolley 10 captures the size parameters of the beam and starts calculations. The intelligent control system computer automatically controls the front trolley 9 and the rear trolley 10 to the appropriate positions at both ends of the beam, puts down the hoist and starts the automatic beam lifting mode. After the bridge is lifted, the intelligent control system controls the front trolley 9 and the rear trolley 10 to run synchronously to the designated position and place the bridge in the appropriate position according to the overall size parameters of the bridge deck captured by the visual 3D high-definition camera, combined with the actions of each sensor. This embodiment facilitates automatic beam lifting by installing a visual 3D camera on each of the front trolley 9 and the rear trolley 10 to monitor the size parameters of the bridge under the bridge erecting machine.

[0037] In some embodiments, the control system may also include: a laser rangefinder, which is arranged at the intersection of the wheel box of the main beam 4 and the middle branch 2, and is used to monitor the distance between the extended end of the main beam 4 and the middle branch 2 in real time, and transmit the distance to the PLC control system; the PLC control system is used to compare the distance with a preset dangerous distance value, and when the distance reaches the preset dangerous distance value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the distance between the extended end of the main beam 4 and the middle branch 2 is automatically adjusted to a preset safe distance value In this embodiment, a laser rangefinder is installed at the wheel box where the middle branch 2 contacts the main beam 4 to monitor the distance between the front end of the main beam 4 and the middle branch 2 in real time. The data is transmitted to the PLC control system. When a dangerous value appears, an alarm is issued or the operation of the bridge erecting machine is stopped, and the distance between the front end of the main beam 4 and the middle branch 2 is automatically adjusted to a safe position.

[0038] In some embodiments, the intelligent control system also includes: a human-computer interaction interface for setting the control data parameters of the bridge-building machine; a human-computer interaction interface for setting the control data parameters of the bridge-building machine, the control data parameters including but not limited to dangerous load value, safe load value, first dangerous inclination value, first safe inclination value, second dangerous inclination value, second safe inclination value, first dangerous displacement value, second dangerous displacement value, third dangerous displacement value, first safe displacement value, second safe displacement value, third safe displacement value, dangerous distance value, safe distance value.

[0039] Intelligent control system refers to the functional control of a complete system combination including human-machine interaction interface (touch screen), PLC control system, expansion module and electrical equipment of executive control mechanism and sensors. The information collected by a series of sensors such as displacement sensor and overload sensor is transmitted to the PLC control system. At the same time, the human-machine interaction interface can be input by human for comprehensive processing. Through the data input by humans, the information will be transmitted to PLC for analysis and processing.

[0040] In some embodiments, the intelligent control system also includes: a number of slave stations and a wireless bridge. The PLC control system controls the number of slave stations through the wireless bridge. The PLC control system obtains data collected by sensors corresponding to different components of the bridge-building machine through the number of slave stations, and then controls the limiters through the corresponding slave stations to limit the various components of the bridge-building machine according to the sensor data.

[0041] Figure 2 is a framework diagram of an intelligent control system of a bridge erecting machine according to an embodiment of the present invention, such as Figure 2As shown, the intelligent control system includes an industrial computer, a touch screen, a remote control platform, a switch, a video monitoring platform, a PLC control system (master PLC), the 1st slave module, the 2nd slave module... the Nth slave module and several other slave modules, the 1st IN / OUT module, the 2nd IN / OUT module... the Nth IN / OUT module, and the 1st analog module, the 2nd analog module... the Nth analog module. The IN / OUT module is a module used for instruction input and execution points; the slave module is a one-to-many control form through the PLC (CPU) control system, that is, the PLC master control system (also known as the PLC master station) can realize a one-to-many control form through multiple slave control to respectively control different detection sensors and other limiters. The limiter controls the limit of each component of the bridge crane according to the sensor data of the sensor. Each detection sensor includes the aforementioned displacement sensor, heavy load sensor, etc., and each limiter controls the limit according to the monitoring data of each sensor. Among them, the IN / OUT module (instruction input and execution point output module) is the module for instruction input and execution point output; the PLC control system (also known as the master station CPU) realizes a one-to-many control form through a number of slave station modules; the data detected by various sensors are transmitted to the slave station module through the analog module, and processed in the main control PLC, and through the remote control platform, video monitoring platform, and data setting on the human-computer interaction interface touch screen, the automatic control of the various components of the bridge-building machine (including the front support 1, the middle support 2, the front crane 9 and the rear crane 10, etc.) is realized under the comprehensive effect of computer-aided calculation.

[0042] In actual work, this embodiment is equipped with a main control cabinet (PLC control system), and three slave control cabinets communicate through wireless bridges to reduce wiring lines and make installation easier. The main control cabinet is the cabinet where the PLC control system (CPU) is located, and the slave control cabinet is the cabinet where the sub-control PLC module that controls the action of each different mechanism is located. They communicate with each other through the PN protocol (PROFINET communication protocol) of Ethernet communication, and form a closed-loop control under the control of various sensors and frequency converters under the comprehensive computer algorithm, thereby ensuring the safe operation of the bridge erection machine under any working conditions.

[0043] An embodiment of the present invention provides an intelligent control system for a bridge erecting machine. The intelligent control system solves the problem that the wheels are easy to derail when out of sync by installing a frequency converter that controls the motor speed. The heavy load sensor installed on the bracket and the displacement sensor on the track solve the risk of the bridge erecting machine tipping over due to eccentric loading. The distance between the main beam 4 and the middle support and the inclination of the main beam 4 are monitored at any time by using a tilt sensor installed on the main beam 4 in conjunction with a laser displacement sensor, thereby ensuring the stability of the main beam 4 during movement and preventing the bridge erecting machine from leaning forward or backward. The intelligent operation of the bridge erecting machine is realized by integrating computer-aided algorithms.

[0044] In addition, the embodiment of the present invention can be switched between automatic mode and manual mode. In the automatic mode, the automatic erection and removal of beams of the bridge erecting machine can be started with one button. If manual adjustment is required, the stop button can be pressed and the operation can be switched to manual mode.

[0045] On the other hand, the embodiment of the present invention also provides an intelligent control method for a bridge erecting machine, such as Figure 3 As shown, the control method includes the following steps: S1, controls the speed of the traverse motors of the front branch 1 and the middle branch 2 on the front branch track 5 and the middle branch track 6 through the frequency conversion controller installed on the front branch 1 and the rear branch 3 according to the control instructions of the PLC control system; S2, controlling the speed of the travel motors of the front crane 9 and the rear crane 10 on the crane track 12 on the main beam 4 through the frequency conversion controller installed on the front crane 9 and the rear crane 10 according to the control instructions of the PLC control system; S3, controlling the speed of the front and rear running motors of the middle branch 2 and the rear support 11 through the frequency conversion controller installed on the middle branch 2 and the rear support 11 according to the control instructions of the PLC control system.

[0046] The embodiment of the present invention controls the motor speed through the frequency converter so that the synchronization of the left and right movement of the front support 1 and the middle support 2 of the bridge erection machine can be effectively controlled, and the synchronization of the left and right wheels of the front trolley 9 and the rear trolley 10 on the track can be effectively controlled, so that the operation of the transverse movement motors of the front support and the middle support is synchronized, the operation of the travel motors of the front trolley and the rear trolley is synchronized, and the operation of the front and rear running motors of the middle support and the rear support is synchronized, so as to avoid derailment caused by inconsistent wheel speeds on both sides of the track.

[0047] Of course, in some embodiments, the method may also include: monitoring the first travel displacement data of the wheel box of the front support 1 relative to the front support track 5, the second travel displacement data of the wheel box of the middle branch 2 relative to the middle branch track 6, and the third travel displacement data of the wheel boxes of the front crane 9 and the rear crane 10 relative to the crane track 12 by means of displacement sensors respectively arranged on the front branch track 5, the middle branch track 6 and the crane track 12, and transmitting the first travel displacement data, the second travel displacement data and the third travel displacement data to the PLC control system respectively; comparing the first travel displacement data, the second travel displacement data and the third travel displacement data with the preset first dangerous displacement value, the second dangerous displacement value and the third dangerous displacement value respectively through the PLC control system, and when the first travel displacement data reaches the first dangerous displacement value, and / or when the second travel displacement data reaches the second dangerous displacement value, and / or when the third travel displacement data reaches the third dangerous displacement value, an alarm is issued or the operation of the bridge erection machine is stopped, and the front support 1, the middle branch 2, the front crane 9 and the rear crane 10 are automatically adjusted to run to the preset first safe displacement value, the second safe displacement value and the third safe displacement value respectively.

[0048] In this embodiment, the displacement sensors installed on one side of the track of the front support 1, the middle support 2, the front trolley 9 and the rear trolley 10 monitor the displacement of the wheel box to the left and right, the tilt sensors installed on the front and rear lock doors of the main beam 4 monitor the tilt angles of the main beam 4 front, back, left and right, and the heavy load sensors installed at each fulcrum monitor the left and right heavy loads of the bridge erecting machine. The comprehensive processing of the data feedback from these three groups of conditions can realize the effective monitoring and control of the overload of the bridge erecting machine.

[0049] For example, taking the overall leftward load of the center of gravity of the bridge erection machine as an example, two displacement points are set on the tracks of the front support 1, the middle support 2, the front crane 9 and the rear crane 10. The values ​​are set in advance in the intelligent control system. The first displacement point is the overload alarm point, and the second point is the forced stop point. When each component moves to the left to the first displacement point, the PLC operation issues a command alarm light to remind that there is a risk of overload. At the same time, the overload sensor at each support point displays the overload data. The intelligent control system has set the maximum allowable value in advance. If the overload weight is within the allowable range, the intelligent control system of the bridge erection machine can continue to control the bridge erection machine components to move to the left and monitor the bridge erection machine status at all times; if the overload weight is greater than or equal to the set allowable value, the program controls the bridge erection machine to stop forcibly, and automatically controls the bridge erection machine components to move to the right to a suitable position. After passing the first point, when reaching the second set point displacement value, this point is the closest to the set maximum overload weight value. At this time, the bridge erection machine is forced to stop running, and then the bridge erection machine components are automatically controlled to move to the right to a suitable position; the same applies to the right overload control.

[0050] In some embodiments, the method may also include: monitoring first inclination angle data of two points in front and behind the main beam 4 through a first inclination sensor installed on the front locking door 7 and the rear locking door 8, and transmitting the first inclination angle data to the PLC control system; comparing the first inclination angle data with a preset first dangerous inclination value through the PLC control system, and when the first inclination angle data reaches the corresponding first dangerous inclination value, sounding an alarm or stopping the bridge erecting machine, and automatically adjusting the front crane 9 and the rear crane 10 to run to the position of the first safe inclination value.

[0051] In this embodiment, the tilt sensors of the front and rear locking doors measure the tilt angle data of the main beam 4 tilting forward or backward, and the PLC control system adjusts the position of the main beam according to the tilt angle data of the front and rear locking doors.

[0052] For example, taking the main beam 4 tilting forward as an example, the tilt sensor installed on the front lock door 7 will display the tilt angle of the main beam 4 forward, and a maximum tilt angle value is set in advance inside the system. When the tilt angle exceeds the set value, the system alarms and controls the bridge erection machine to forcibly stop running through PLC operation, and then automatically controls the bridge erection machine parts to run in the opposite direction to the appropriate position. On the contrary, the tilt of the main beam 4 backward is controlled by the tilt sensor installed on the rear lock door 8 in the same way.

[0053] In some embodiments, the method may also include: monitoring second inclination angle data of the wire rope by means of a second inclination sensor arranged on the wire rope of the front crane 9 and the rear crane 10, and transmitting the second inclination angle data to the PLC control system; comparing the second inclination angle data with a preset second dangerous inclination value through the PLC control system, and when the second inclination angle data reaches the corresponding second dangerous inclination value, sounding an alarm or stopping the operation of the bridge erecting machine, and automatically adjusting the front crane 9 and the rear crane 10 to run to the position of the second safe inclination value.

[0054] For example, taking the steel wire rope tilting forward as an example, during the process of lifting the beam, when the steel wire rope on one side tilts forward, the tilt sensor vertically fixed on a fixed steel wire rope will display the forward tilt angle, and a maximum tilt angle value is set in advance inside the intelligent control system. The computer of the PLC control system performs calculations. If the current tilt angle exceeds the set maximum tilt angle value, an alarm is issued and the bridge erection machine is controlled to forcibly stop running, and the front crane or the rear crane is automatically controlled to run in the opposite direction to the appropriate position. The backward tilt of the steel wire rope is controlled in the same way. In this embodiment, the tilt sensor fixed on a steel wire fixed by a pulley can effectively monitor the tilt angle of the steel wire rope.

[0055] In some embodiments, in order to facilitate automatic beam lifting, the method may also include: the dimensional parameters of the bridge can be monitored by a visual 3D camera installed on the front crane 9 and the rear crane 10, and the dimensional parameter values ​​are transmitted to the PLC control system; the PLC control system calculates the target positions of the front crane 9 and the rear crane 10 at the two ends of the main beam 4 according to the dimensional parameters of the bridge, and when the front crane 9 and the rear crane 10 move to the target position, the slings are lowered to start the automatic beam lifting mode.

[0056] For example, after the bridge is transported to the bottom of the bridge erection machine, a visual 3D camera installed on each of the front crane 9 and the rear crane 10 captures the size parameters of the bridge and starts calculation. The computer of the PLC control system automatically controls the front crane 9 and the rear crane 10 to run to the appropriate positions (i.e., the target positions) at both ends of the main beam, and puts down the hoist to start the automatic beam lifting mode. After the bridge is hoisted, according to the overall size parameters of the bridge deck captured by the visual 3D camera, the PLC control system controls the front crane 9 and the rear crane 10 to run synchronously to the specified position and place the bridge in the appropriate position in combination with the actions of each sensor.

[0057] The embodiment of the present invention comprehensively uses heavy-load sensors, displacement sensors, tilt sensors and other limiters to increase the safety and reliability of operation, and controls the speed of the motor through a frequency converter to ensure the synchronization of the motor; and adopts human-computer interaction interface control, and is equipped with a visual interface system. By measuring the three-dimensional size parameters of the beam, the computer automatically calculates and combines with the PLC control system to realize intelligent control of the bridge erection machine.

[0058] The intelligent control system of the embodiment of the present invention has the following beneficial effects: The present invention realizes synchronous control of different supporting and moving parts of the bridge erecting machine through an intelligent control system including a PLC and a frequency conversion controller, thereby improving the stability and reliability of equipment operation and reducing the risk of derailment caused by asynchrony.

[0059] The present invention monitors the load of each supporting point in real time by adding a heavy-load sensor. When the load reaches a dangerous value, it can automatically make safety adjustments to improve the safety of the equipment.

[0060] The present invention monitors the inclination angle of the main beam through the first inclination sensor, provides real-time inclination monitoring and automatic adjustment, and prevents safety hazards caused by the inclination.

[0061] The present invention arranges a second inclination sensor to monitor the inclination of the steel wire rope, thereby improving the stability and safety of the bridge erecting machine during the lifting operation.

[0062] The present invention monitors the relative displacement of each component through a displacement sensor, thereby improving the accuracy of positioning and avoiding the phenomenon of eccentric loading.

[0063] The present invention achieves accurate measurement and monitoring of beam dimensions by installing a 3D high-definition camera on an overhead crane, assists in automatic beam lifting, and realizes intelligent operation.

[0064] The present invention monitors the distance between key components in real time through a laser rangefinder, ensures a safe distance during operation, and reduces the risk of misoperation.

[0065] The present invention uses a human-machine interactive interface, so that operators can set and monitor parameters, thereby enhancing the convenience of operation and control accuracy.

[0066] The present invention utilizes a wireless network bridge to realize communication between a PLC and a slave station, reduces wiring complexity, and improves the flexibility and working efficiency of an intelligent control system.

[0067] The energy control method of the present invention further ensures the safety and stability of the bridge erection machine operation by synchronously controlling the motor speeds of different components.

[0068] The present invention greatly improves the intelligence and automation level of the bridge erecting machine, improves the operating efficiency, and at the same time significantly reduces the operating risk, thereby ensuring construction safety.

[0069] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims

1. An intelligent control system for a bridge erecting machine, characterized in that: The intelligent control system comprises: a front support (1), a middle support (2), a rear support (3), a main beam (4), a front support track (5), a middle support track (6), a front locking door (7), a rear locking door (8), a front crane (9), a rear crane (10) and a rear support (11); The front support (1) and the rear support (3) are used to support the main beam (4); The front crane (9) and the rear crane (10) are arranged on a crane track (12) on the main beam (4), and move forward and backward along the crane track (12) on the main beam (4); The front locking door (7) and the rear locking door (8) are arranged at two ends of the main beam (4) and are used to connect the main beam (4); The front branch (1) is arranged on the front branch track (5) and moves left and right along the front branch track (5); The middle support (2) and the rear support (11) are arranged below the main beam (4) and are used to support the main beam (4) so ​​that the main beam (4) moves back and forth along the span direction; The middle branch (2) is arranged on the middle branch track (6) and moves left and right along the middle branch track (6); The intelligent control system also includes: a PLC control system and a plurality of frequency conversion controllers; The multiple frequency conversion controllers are respectively installed on the front support (1), the middle support (2), the front crane (9), the rear crane (10) and the rear support (11). The frequency conversion controllers are used to control the rotation speed of the transverse motors of the front support (1) and the rear support (3), the rotation speed of the travel motors of the front crane (9) and the rear crane (10), and the rotation speed of the front and rear running motors of the middle support (2) and the rear support (11) according to the control instructions of the PLC control system, so that the transverse motors of the front support (1) and the middle support (2) operate synchronously, the travel motors of the front crane (9) and the rear crane (10) operate synchronously, and the front and rear running motors of the middle support (2) and the rear support (11) operate synchronously.

2. The intelligent control system of a bridge erecting machine according to claim 1 is characterized in that: The intelligent control system also includes: A plurality of heavy load sensors are respectively arranged at the flange connection of the front support (1), the leg connection of the middle support (2) and the connection of the rear support (11), and are used to monitor the load data of the points where the front support (1), the middle support (2) and the rear support (11) contact the main beam (4); and transmit the load data to the PLC control system; The PLC control system is used to compare the load data of each point with the preset dangerous load value of each point. When the load data reaches the dangerous load value corresponding to each point, an alarm is issued or the operation of the bridge erection machine is stopped, and the front support (1), the middle support (2) and the rear support (11) are automatically adjusted to run to positions corresponding to the safe load values.

3. The intelligent control system of a bridge erecting machine according to claim 2 is characterized in that: The intelligent control system also includes: First inclination sensors are respectively mounted on the front locking door (7) and the rear locking door (8), and are used to monitor first inclination angle data of two points in front and behind the main beam (4), and transmit the first inclination angle data to the PLC control system; The PLC control system is used to compare the first inclination angle data with a preset first dangerous inclination value, and when the first inclination angle data reaches the corresponding first dangerous inclination value, an alarm is issued or the operation of the bridge erection machine is stopped, and the front crane (9) and the rear crane (10) are automatically adjusted to operate to the position of the first safe inclination value.

4. The intelligent control system of a bridge erecting machine according to claim 3 is characterized in that: The intelligent control system also includes: Second inclination sensors are respectively arranged on the steel wire ropes of the front crane (9) and the rear crane (10), and are used to monitor second inclination angle data of the steel wire ropes and transmit the second inclination angle data to the PLC control system; The PLC control system is used to compare the second inclination angle data with a preset second dangerous inclination value. When the second inclination angle data reaches the corresponding second dangerous inclination value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the front crane (9) and the rear crane (10) are automatically adjusted to operate to the position of the second safe inclination value.

5. The intelligent control system of a bridge erecting machine according to claim 4 is characterized in that: The intelligent control system also includes: A plurality of displacement sensors are respectively arranged on the front branch track (5), the middle branch track (6) and the overhead crane track (12), and are used to monitor first travel displacement data of the wheel box of the front branch (1) relative to the front branch track (5), second travel displacement data of the wheel box of the middle branch (2) relative to the middle branch track (6), and third travel displacement data of the wheel boxes of the front overhead crane (9) and the rear overhead crane (10) relative to the overhead crane track (12), and transmit the first travel displacement data, the second travel displacement data and the third travel displacement data to the PLC control system respectively; The PLC control system is used to compare the first walking displacement data, the second walking displacement data and the third walking displacement data with a preset first dangerous displacement value, a second dangerous displacement value and a third dangerous displacement value, respectively. When the first walking displacement data reaches the first dangerous displacement value, and / or when the second walking displacement data reaches the second dangerous displacement value, and / or when the third walking displacement data reaches the third dangerous displacement value, an alarm is issued or the operation of the bridge erecting machine is stopped, and the front support (1), the middle support (2), the front crane (9) and the rear crane (10) are automatically adjusted to run to the preset first safe displacement value, the second safe displacement value and the third safe displacement value, respectively.

6. The intelligent control system of a bridge erecting machine according to claim 5, characterized in that: Visual 3D cameras are respectively installed on the front crane (9) and the rear crane (10) to monitor the size parameters of the bridge; The PLC control system is used to calculate the target positions of the front crane (9) and the rear crane (10) at the two ends of the main beam (4) according to the size parameters of the bridge, and when the front crane (9) and the rear crane (10) move to the corresponding target positions, the lifting devices are lowered to start the automatic beam lifting mode.

7. The intelligent control system of a bridge erecting machine according to claim 6, characterized in that: The intelligent control system also includes: a laser rangefinder, arranged at the intersection of the main beam (4) and the wheel box of the middle branch (2), for real-time monitoring of the distance between the extended end of the main beam (4) and the middle branch (2), and transmitting the distance to the PLC control system; The PLC control system is used to compare the distance with a preset danger distance value, and when the distance reaches the preset danger distance value, an alarm is issued or the operation of the bridge erection machine is stopped, and the distance between the extended end of the main beam (4) and the middle branch (2) is automatically adjusted to a preset safety distance value.

8. The intelligent control system of a bridge erecting machine according to claim 7, characterized in that: The intelligent control system also includes: A human-computer interaction interface is used to set the control data parameters of the bridge-building machine, and the control data parameters include at least one of the following: dangerous load value, safe load value, first dangerous inclination value, first safe inclination value, second dangerous inclination value, second safe inclination value, first dangerous displacement value, second dangerous displacement value, third dangerous displacement value, first safe displacement value, second safe displacement value, third safe displacement value, dangerous distance value, and safe distance value.

9. The intelligent control system of a bridge erecting machine according to claim 8, characterized in that: The intelligent control system also includes: A plurality of slave stations and wireless bridges, the PLC control system controls the plurality of slave stations through the wireless bridges, the PLC control system obtains data collected by sensors corresponding to different components of the bridge-building machine through the plurality of slave stations, and controls the limiters through the corresponding slave stations to limit the various components of the bridge-building machine according to the sensor data.

10. An intelligent control method for a bridge erecting machine, the method being applied to the intelligent control system of the bridge erecting machine according to any one of claims 1 to 9, characterized in that: The intelligent control method comprises: The frequency conversion controllers installed on the front branch (1) and the rear branch (3) control the rotation speeds of the transverse motors of the front branch (1) and the middle branch (2) on the front branch track (5) and the middle branch track (6) according to the control instructions of the PLC control system, so that the transverse motors of the front branch (1) and the middle branch (2) operate synchronously; The frequency conversion controllers installed on the front crane (9) and the rear crane (10) control the rotation speeds of the travel motors of the front crane (9) and the rear crane (10) on the crane track (12) on the main beam (4) according to the control instructions of the PLC control system, so that the travel motors of the front crane (9) and the rear crane (10) operate synchronously; The frequency conversion controller installed on the middle support (2) and the rear support (11) controls the rotation speed of the front and rear running motors of the middle support (2) and the rear support (11) according to the control instructions of the PLC control system, so that the front and rear running motors of the middle support (2) and the rear support (11) operate synchronously.

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