Self-adaptive under-actuated portal crane anti-swing and anti-top-rushing system and method

Abstract

The invention discloses a self-adaptive under-actuated portal crane anti-swing and anti-top-rushing system and method, and relates to the technical field of cranes. The self-adaptive under-actuated portal crane anti-swing and anti-top-rushing system comprises a software simulation platform and a hardware simulation platform; the hardware simulation platform is provided with a control system and a vision measurement module; the software simulation platform simulates the motion trail of transporting and hoisting goods in the working scene where the actual portal machine is located, and a control simulation model, an anti-swing model and an anti-top-rushing model of the motion trail are constructed; the hardware simulation platform builds a door-seat machine transportation model based on the size of a real door-seat machine and a working scene of the real door-seat machine; and the control system is in data communication connection with the software simulation platform, and controls the movement of the portal machine transportation model based on track control parameters obtained by the control simulation model constructed by the software simulation platform, so that the simulation of the actual transportation condition of the portal machine is realized, and further the training and verification of the control simulation model, the anti-swing model and the anti-top-rushing model are completed. According to the system, the deviation self-adaptability and the transportation stability during transportation are guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of cranes, and in particular to an adaptive under-actuated gantry crane anti-sway and anti-top-impact system and method. Background Art

[0002] Gantry cranes are widely used in bulk cargo unloading operations at seaport terminals. During the normal operation of the gantry crane, the completion of an operation cycle is mainly achieved by the variable amplitude movement of the transport crane mechanism of the ship unloader and the lifting and lowering movement of the rope controlled by the hoisting rope motor mechanism. Due to the inertia of each mechanism during acceleration and deceleration and the control system in the system cannot directly apply force or torque to change the degree of freedom of each mechanism. This means that under the influence of inertia, the movement state of the hoisting weight during the operation will lag behind or lead the movement of the mechanism. This part of the lag or advance will cause the hoisting rope mechanism to swing back and forth around the crane and the load to rush to the top. In this case, it is very important to indirectly control these degrees of freedom through appropriate algorithms and technologies. Under an operating cycle, if the swing angle and rising speed of the hoisting weight are not effectively controlled, the following problems will occur: First, when the gantry crane lifts or lowers cargo, or moves the load horizontally, if the operation is improper, the cargo and the connected lifting rope may swing. The swing angle generated by the lifting rope and the cargo provides the initial disturbance of the system and generates inertial force, causing the load to swing and eventually stop under the action of friction and wind resistance, but this process lasts for a long time.

[0003] Second, the crane rope lifting equipment collides or overshoots when approaching the top position. In some cases, the rapidly rising load may be difficult to stop immediately due to inertia, resulting in the risk of collision with the top transport crane structure.

[0004] The above problems greatly reduce the operating efficiency and safety of the gantry crane.

[0005] At present, there are technical solutions for preventing gantry cranes from swinging and hitting the top. Some electronic control systems based on sensor feedback can monitor the position and speed of the hook in real time, and slow down or stop the movement of the hook by adjusting the speed and direction of the motor. Traditional mechanical limiters can limit the maximum stroke of the hook through physical contact, thereby avoiding overshoot.

[0006] Although existing technologies have achieved certain results, there are still some shortcomings. On the one hand, traditional electronic control systems that rely on fixed parameter settings lack flexibility and perform poorly when faced with different load conditions or changes in the external environment. On the other hand, traditional mechanical limit methods have slow response speeds and low precision, making it difficult to meet the needs of high-speed and high-precision operations. In addition, these systems often cannot handle the influence of nonlinear factors well, such as sudden wind changes or complex load characteristics, resulting in poor system robustness and inability to ensure long-term stable operation. Summary of the invention In view of this, the present invention aims to provide an adaptive under-actuated door crane anti-sway and anti-top-collision system and method to solve the problems of hanging weight sway and top-collision caused by load uncertainty, parameter changes and external interference during the operation of the existing adaptive under-actuated door crane.

[0007] To this end, the present invention adopts the following technical solutions: On the one hand, the present invention discloses an adaptive under-actuated door machine anti-sway and anti-top-impact system, comprising: a software simulation platform and a hardware simulation platform; the hardware simulation platform is configured with a control system and a visual measurement module; The software simulation platform simulates the motion trajectory of transporting hoisted goods in the working scene of the real gantry crane, and constructs a control simulation model, a swing elimination model and an anti-top impact model of the motion trajectory; The hardware simulation platform builds a portal machine transportation model based on the size of the actual portal machine and its working scene; the control system controls the movement of the portal machine transportation model based on the trajectory control parameters obtained from the control simulation model built by the software simulation platform, so as to simulate the actual transportation situation of the portal machine and train and verify the anti-sway model and the anti-top impact model; The visual measurement module includes an industrial visual camera and a binocular visual system installed in a suspended safety position on the portal machine model, wherein the industrial visual camera is used to collect images of the hoisted cargo and the suspension rope, and the binocular visual system detects the length of the steel wire rope of the suspended load and the swing angle of the suspension rope based on the collected images; The training and verification of the anti-sway model and the anti-top-impact model include: The visual measurement module feeds back the detected wire rope length of the hanging load to the anti-collision model of the software simulation platform to obtain the anti-collision control parameters. The control system controls the movement of the gantry crane transport model based on the anti-collision control parameters to prevent the cargo from collide with the transport track obstacles due to the slow rope collection speed. The visual measurement module feeds back the detected swing angle of the suspension rope to the anti-swing model of the software simulation platform to obtain the anti-swing control parameters. The control system controls the movement of the gantry crane transport model based on the anti-swing control parameters to prevent the suspension rope from swinging too much.

[0008] Furthermore, a door-to-door transport model is built, including: A proportionally scaled inverted T-shaped portal machine model is constructed; the portal machine model comprises: a base, a main beam erected at the center of the base, and a crossbeam firmly installed on the top of the main beam; Install a lifting mechanism and a position sensor for monitoring the lifting height on the main beam; A traveling mechanism is installed under the crossbeam, which can move smoothly along the main beam to simulate the process of the gantry crane traveling along the dock track; A sling simulation device is fixed on the crossbeam, and the sling simulation device can rotate and tilt freely so as to simulate various actions under real working conditions; Install force sensors to detect the interaction force between the spreader and the cargo; A sensor system for monitoring the motion status during operation is installed on the top of the main beam and at the connection of the spreader simulation device; The configuration is responsible for receiving data from the software simulation platform and adjusting the control system of the motor output according to the received data.

[0009] Furthermore, a dynamic model simulating the movement trajectory of cargo in a door-mounted crane is constructed, including: Determine the physical parameters of the portal crane transport model, including: the mass of the portal crane trolley 、 The length of the wire rope that suspends the load, the driving force of the rope to lift it, and the load swing angle; Based on the physical parameters of the portal crane transportation model, the Lagrangian method is used to establish a nonlinear dynamic model for simulating the movement trajectory of the portal crane cargo; the nonlinear dynamic model includes: the Lagrangian equations of the crossbeam component of the lifting driving force of the lifting rope, the lifting driving force of the lifting rope and the swing angle during the lifting of the cargo.

[0010] Furthermore, a swing elimination model is constructed, including: The nonlinear dynamic model of the simulated gantry crane cargo motion trajectory is analyzed in two-dimensional phase plane, and a swing elimination model based on the shaping algorithm is established under the zero initial state to obtain the relationship between the load swing angle and the crane displacement acceleration as well as the maximum and minimum values ​​of the load swing angle. Among them, the relationship between the load swing angle and the crane displacement acceleration is: ; in, is the crane displacement acceleration, For the quality of the gantry crane trolley, is the load swing angle, is the acceleration due to gravity, For the quality of goods, It is the beam force component of the lifting driving force of the rope; The maximum and minimum values ​​of the load swing angle are: ; in, is the maximum load swing angle, is the minimum load swing angle, is a constant, g is the acceleration due to gravity, is the initial value of the load swing angle, is the initial value of the load swing angular velocity; Based on the maximum and minimum values ​​of the load swing angle, a constraint condition of the load swing angle is determined; the constraint condition of the load swing angle is: the maximum and minimum values ​​of the load swing angle are respectively less than a preset angle.

[0011] Furthermore, the visual measurement module feeds back the detected swing angle of the suspension rope to the anti-swing model of the software simulation platform to obtain anti-swing control parameters, including: Based on the swing angle of the suspension rope detected by the visual measurement module, the relationship between the load swing angle and the crane displacement acceleration is used to obtain the crane displacement acceleration and whether the current swing angle direction is in the same direction or in the opposite direction of the crane movement direction; The control system controls the movement of the portal crane transport model based on the anti-sway control parameter to prevent the suspension rope from swinging too much, including: When the load swing angle does not meet the constraint conditions, if the current swing angle direction is in the same direction as the crane movement direction, the acceleration of the crane running motor is increased; if the current swing angle direction is in the opposite direction to the crane movement direction, the acceleration of the crane running motor is reduced.

[0012] Furthermore, an anti-roofing model is constructed, including: The left and right views of the cargo transported by the gate machine collected in real time by the binocular industrial vision camera in the visual measurement module are stereo corrected to obtain the internal and external parameters of the binocular industrial vision camera; the internal and external parameters of the binocular industrial vision camera include: binocular baseline distance T , Camera focal length f , the reference point in the world coordinate system with the left camera as the reference , where the coordinate Z represents the length of the wire rope that suspends the load l ; The component of the X direction in the two image coordinate systems of the point projection on the left and right image planes is , get the projection parallax of the left and right images d : ; Based on the parallax of left and right screen projection d The rope distance measurement formula is obtained: ; Calculate the rope ascent or descent distance under fixed time sampling ,speed : ; Among them, k is the change value; ; The constraints must be met: ; in, is the minimum rope speed, is the maximum rope speed.

[0013] Furthermore, the visual measurement module feeds back the detected length of the wire rope of the suspended load to the anti-top impact model of the software simulation platform to obtain the anti-top impact control parameters, including: Based on the length of the wire rope of the suspended load detected by the visual measurement module, the speed deviation is obtained. - or - ; The control system controls the movement of the portal crane transport model based on the anti-collision control parameter to prevent the cargo from collide with the transport track obstacle due to the slow rope collection speed, including: when If the constraints are not met, Greater than ,by - The speed deviation reduces the rope motion motor speed. Less than ,by - The speed deviation increases the rope motion motor speed.

[0014] On the other hand, the present invention further provides an adaptive under-actuated door machine swing elimination and top collision prevention method, the method uses the above-mentioned adaptive under-actuated door machine swing elimination and top collision prevention system to eliminate swing and prevent top collision, and the method comprises the following steps: Step 1: Simplify the actual door-to-door crane transportation process and obtain the simulation parameters of the door-to-door crane transportation process under proportional scaling; Step 2: Based on the simulated parameters of the gantry crane transportation process under scaled conditions, the motion trajectory of the gantry crane in transporting hoisted cargo in the actual working scenario is simulated, and a control simulation model, a swing elimination model, and an anti-top impact model of the motion trajectory are constructed; Step 3: Based on the simulated parameters of the portal crane transportation process under scale, the portal crane transportation model is built in combination with the size of the actual portal crane and its working scene; Step 4: Using the trajectory control parameters obtained by the control simulation model to control the movement of the portal crane transportation model, so as to simulate the actual transportation situation of the portal crane; Step 5: Training and verification of the anti-sway model and anti-top-impact model, including: The industrial vision camera collects images of the hoisted cargo and the suspension rope in real time, and the binocular vision system detects the length of the wire rope hanging the load and the swing angle of the suspension rope based on the collected images; Feeding back the detected length of the wire rope of the hanging load to the anti-collision model to obtain the anti-collision control parameters, and controlling the movement of the gantry crane transport model based on the anti-collision control parameters to prevent the cargo from collide with the transport track obstacles due to the slow rope collection speed; Feeding back the detected swing angle of the suspension rope to the anti-swing model to obtain the anti-swing control parameter, and controlling the movement of the portal crane transport model based on the anti-swing control parameter to prevent the suspension rope from swinging too much; Step 6: Apply the trained and verified control simulation model, sway elimination model and top impact prevention model to the actual adaptive under-actuated door crane to achieve sway elimination and top impact prevention of the actual adaptive under-actuated door crane.

[0015] Furthermore, based on the simulated parameters of the gantry crane transportation process under proportional scaling, the motion trajectory of the gantry crane in transporting hoisted cargo in the actual working scene is simulated, and a control simulation model, a swing elimination model and a top impact prevention model of the motion trajectory are constructed, including: Determine the target trajectory that the door-to-door aircraft needs to follow to deliver the goods; Based on the time required to complete the entire movement with the actual driving force obtained, define the position the system should be in at each moment and determine the speed at each position; define the change in acceleration to ensure the smoothness of the movement; Set the number of continuous state variables, the number of discrete state variables, the number of outputs, and the number of inputs; The reference shaping algorithm uses cubic spline interpolation in S-curve trajectory planning to smooth the changes in crane motion acceleration; Use minimum beat control to transfer the system from one state to another in the shortest time and reduce overshoot; Pre-oscillation compensation is performed before the action starts, introducing a small pre-oscillation to offset the swing caused by the subsequent action and make the model more stable.

[0016] Furthermore, the actual gantry crane transportation process is simplified, including: simplifying the actual gantry crane transportation process into a process without initial speed, first accelerating to the maximum speed and then to the stable speed from the feeding point to the picking point, and then decelerating to 0m / s to the picking point.

[0017] The beneficial effect of the present invention is that through the synergy of the software simulation platform and the hardware simulation platform, the accurate simulation and optimized control of the gantry crane transportation process are realized. On the one hand, the motion trajectory control, swing elimination and anti-top collision model constructed by the software simulation platform provide a theoretical basis for the efficient operation of the gantry crane; on the other hand, the hardware simulation platform combines the visual measurement module to collect image information of goods and ropes in real time, and feed it back to the simulation platform for model training and verification to ensure the accuracy and adaptability of the control parameters. The introduction of the visual measurement module enables the system to monitor the length of the wire rope and the swing angle of the suspension rope in real time, and then accurately adjust the control parameters to effectively prevent the goods from hitting the top or colliding with obstacles, and avoid the suspension rope from swinging too much. This innovative method combining virtual simulation with actual measurement not only improves the operating efficiency and safety of the gantry crane, but also enhances the robustness and adaptability of the system, reduces the risk of accidents caused by operating errors or environmental interference, and provides an efficient and reliable solution for gantry crane transportation in complex operating environments such as ports. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0019] Figure 1 The scaled model after the actual data is processed by the embodiment of the present invention is shown; Figure 2 A schematic diagram showing a two-dimensional simplification of an actual door station in an embodiment of the present invention is shown; Figure 3 A schematic diagram of the binocular ranging principle in an embodiment of the present invention is shown; Figure 4 A flow chart of a method for adaptively preventing swing and top impact of an under-actuated door machine in an embodiment of the present invention is shown; Figure 5 A control flow chart showing the implementation principle of the present invention is shown. DETAILED DESCRIPTION

[0020] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0021] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0022] The embodiment of the present invention provides an adaptive under-actuated door machine anti-sway and anti-top-impact system, including: a software simulation platform and a hardware simulation platform; wherein: The software simulation platform is used to obtain the motion data of the track under normal operation from the actual database of the actual gantry machine angle and the crane rope retracting driving force. The closed-loop control model is first established through the shaping algorithm and non-dynamic formula, and the XZ trajectory model of the forward and backward swing under the two-dimensional coordinates and the associated motion speed and acceleration under the change of the rope length are simulated to simulate the actual situation. In addition, the software simulation platform also constructs the anti-swing model and the anti-top model to realize the adaptive under-actuated gantry machine anti-swing and anti-top.

[0023] The hardware simulation platform is used to build a simulated door-to-door transport model, which is a scaled model after processing the actual data (such as Figure 1 As shown in the figure), the actual motion parameters are simulated, the acceleration time and the swing angle are simulated indoors, and the mass of the actual crane and the associated grab bucket and the above speed and other parameters are reasonably scaled to ensure that the motion state of the object is similar to the actual state under proportional scaling, especially the same swing angle, which is convenient for anti-sway testing when applied in actual practice.

[0024] The hardware simulation platform is equipped with a control system and a visual measurement module. The control system is connected to the software simulation platform through data communication. The trajectory control parameters obtained from the control simulation model built on the software simulation platform control the movement of the gantry crane transport model, thereby simulating the actual transportation situation of the gantry crane and training and verifying the anti-swing model and anti-top impact model.

[0025] The visual measurement module includes an industrial vision camera and a binocular vision system installed in a suspended safety position on the portal machine model. The industrial vision camera is used to collect images of the hoisted cargo and the suspension ropes. The binocular vision system detects the length of the steel wire rope of the suspended load and the swing angle of the suspension rope based on the collected images. The training and verification of the anti-swing model and the anti-top impact model include: the visual measurement module is connected to the software simulation platform for data communication, and the detected length of the wire rope of the suspended load is fed back to the anti-top impact model of the software simulation platform to obtain the anti-top impact control parameters. The control system controls the movement of the gantry crane transport model based on the anti-top impact control parameters to prevent the cargo from hitting the top or colliding with obstacles on the transport track due to slow rope collection speed; the visual measurement module feeds back the detected swing angle of the suspension rope to the anti-swing model of the software simulation platform to obtain the anti-swing control parameters. The control system controls the movement of the gantry crane transport model based on the anti-swing control parameters to prevent the suspension rope from swinging too much.

[0026] The above-mentioned adaptive under-actuated gantry crane anti-sway and anti-top-impact system is composed of three links when in use, including: a software simulation link, a hardware simulation link and a visual measurement feedback link.

[0027] The simulation software platform uses a closed-loop control shaping algorithm to simulate the two-dimensional XZ axis trajectory of the gantry crane's cargo pickup trajectory, and simulates it on the hardware simulation platform at the same time to ensure that its movement ratio is consistent with that of the actual gantry crane, and strictly controls the degree of similarity between its swing angle and the actual swing angle to simulate the actual transportation situation to the maximum extent, and finally adds an anti-sway model for anti-sway processing, and adds an anti-top impact model for anti-top impact processing.

[0028] In the visual measurement feedback link, a binocular industrial camera is used to take pictures of cargo and telescopic equipment, detect the length of the steel wire rope of the suspended load and the swing angle of the suspension rope, and the obtained data is used for data adjustment of the simulation software platform. Finally, the control system is used for motor control, and the hardware simulation platform is used to train and verify the anti-sway model and anti-top impact model, which are finally used for actual adaptive under-actuated gantry crane anti-sway and anti-top impact.

[0029] The anti-sway model is described in detail below: The two-dimensional plane diagram is as follows Figure 2Firstly, reasonable assumptions are made to analyze the Newtonian mechanics of the gantry crane trolley under different initial conditions, and the system space model is simplified into two-dimensional plane space through decoupling analysis. Only the movement of the gantry crane trolley in the XZ axis is analyzed, so as to establish the anti-sway mathematical model of the gantry crane.

[0030] in, For the quality of the gantry crane trolley, is the length of the wire rope for hanging the load, Provides driving force for wire ropes. is the load swing angle. The gantry crane trolley only moves in the X-axis direction, and its position coordinates can be expressed as The load can move in the XOZ plane, and the position coordinates can be expressed as ( ), and the position coordinate relationship with the gantry crane trolley is: ; Relationship between load and trolley speed: ; The energy analysis of the bridge gantry system is carried out, and the Lagrange equation is established. The mathematical model of the bridge gantry system is obtained by solving it. The kinetic energy of the gantry system includes the kinetic energy of the gantry trolley and the kinetic energy of the load. The structure of the gantry trolley has no effect on the motion state of the system. At the same time, the gantry trolley only moves on the X axis, so the kinetic energy of the trolley is for: ; The load of the portal machine swings in the XOZ plane, so its speed is synthesized by the speed in the X and Z directions. : ; The load speed of the portal machine is divided into the X and Z directions respectively. , .

[0031] The kinetic energy of the crane load can be obtained for: ; The displacement speed of the gantry crane trolley is The total kinetic energy of the system is: ; The potential energy is: ; For a two-dimensional underactuated crane system, there are three generalized coordinate variables, namely . is the displacement of the trolley , is the displacement of the crane wire rope , is the swing angle of the crane load . is the generalized non-conservative force of the system. L is the Lagrangian operator of the system, ; Where T represents the kinetic energy in the crane system, which is the sum of the kinetic energy of the crane trolley and the crane load. Substituting U for the potential energy of the crane system during motion, we establish the Lagrange equation. We get: ; according to: ; Get the beam force component of the lifting driving force of the suspension rope along the direction of the wire rope The Lagrange equation is: ; The generalized coordinate variables moving along the wire rope direction l Establish the direction of wire rope movement The Lagrange equation is: ; Swing angle θ Establish the generalized Lagrangian equation: ; The nonlinear dynamic equation of the underactuated crane system moving in the XOZ plane is obtained as follows: ; The state space equation is established based on the mathematical model of the system to verify the stability and controllability of the system. The relationship between the load swing state and the initial state and acceleration is analyzed by the phase plane method: ; Get the spatial expression correlation coefficient: ; Indicates 4 4 represents the identity matrix, and 0 represents the zero matrix.

[0032] The phase plane analysis of the second-order system image algorithm is performed on the dynamic equation of the portal crane system. When the swing angle of the single pendulum motion is less than 10°, the swing period T is only related to the rope length, T= , so the natural frequency = ,Will Bring in the rearrangement: ; When the crane system acceleration is constant and positive, the crane load swing angle will be at the maximum value of , the minimum value is , and by For the cycle from point It starts to move periodically clockwise along the circular trajectory of the phase plane. is a constant.

[0033] ; Under the initial load condition, when there is no driving force, the input and resistance input meet the following conditions: ; Then the simple pendulum motion in the initial state satisfies: ; The radius of the phase plane circle is = , get the starting point of the periodic motion : ; It is further explained that the initial swing angle of the crane load is ), the swing angular velocity is , the crane trolley acceleration is a periodic motion. This provides a theoretical basis for further realizing the crane shaping input anti-sway in a non-zero initial state.

[0034] The following is a detailed description of the anti-top model: Use the software simulation platform MATLAB to calibrate the left and right cameras separately, and then perform stereo correction to obtain accurate camera internal and external parameters to obtain the binocular baseline distance of the binocular camera device , camera focal length , the left camera is the reference point in the world coordinate system ,like Figure 3 where the coordinate Z can be used for the length of the wire rope that suspends the load , calculate the rope ascent or descent distance and speed . The component of the X direction in the two image coordinate systems of the point projection on the left and right image planes is , get the projection parallax of the left and right images : ; The rope distance measurement formula is obtained: ; The change of rope length is obtained by sampling at fixed time, and the change value isk =0,1,2

[0035] ; Get the speed expression relationship: .

[0036] A DS-2CD3367WDP2V2-L binocular industrial vision camera is installed in a safe position on the model suspension of the simulated bucket crane. A real-time binocular vision system based on FPGA algorithm and stereo matching algorithm is used to detect the rising distance and swing angle changes of the suspended cargo. MATLAB is used to calibrate the left and right cameras separately, and then binocular calibration is performed to obtain accurate internal and external parameters of the camera. Finally, the Bouguet algorithm is used to complete the stereo correction of the left and right views of the binocular camera.

[0037] The hardware simulation link of the present invention needs to be constructed and trained through actual data and an initial closed-loop model before the system is officially installed, and only then does it need to obtain feedback through visual measurement return values.

[0038] like Figure 5 As shown, the working principle of the present invention mainly relies on the anti-sway model, the anti-top model and the simulated actual data collection, and then the anti-sway processing is performed on the actual gantry crane transportation acceleration and deceleration by detecting the shaking angle as the output, and the anti-top processing is performed on the actual lifting rope expansion and contraction speed and acceleration by measuring the load movement speed and acceleration as the output. The anti-sway model and the anti-top model that can predict the normal working state are trained through a large number of normal events in the database. When the gantry crane is working, the visual measurement module composed of the DS-2CD3367WDP2V2-L binocular industrial vision camera works, and the initial data is transmitted as input to the control system based on the shaping algorithm and the anti-sway model of the industrial camera angle measurement. If there is a load shaking angle exceeding the preset angle (such as 10 degrees) based on the central vertical line, the acceleration of the crane needs to be adjusted, and the adjustment signal is transmitted to the crane motion motor in the hardware simulation platform configuration control system, and the control motor is controlled by the feedback signal. If there is no load shaking angle exceeding the specified angle range, the existing motion state is maintained. The anti-top model is based on the visual measurement module to detect the length of the wire rope of the suspended load. According to the collection of continuous distance data, the speed deviation is obtained - or - ;when The constraints are not met ( The constraints must be met: ;in, is the minimum rope speed, is the maximum rope movement speed. ) enters this link and provides the hardware control system with the rope movement motor response feedback (if Greater than ,by - The speed deviation reduces the rope motion motor speed. Less than ,by - The speed deviation increases the rope motion motor speed. ).

[0039] In another embodiment, the present invention provides a method for eliminating swing and preventing top impact when using the above-mentioned anti-swing and anti-top impact system to transport hoisted goods by a multi-faceted gantry crane or other hoisting machinery, such as Figure 4 As shown, the specific steps include: Step 1: Simplify the actual door-to-door crane transportation process and obtain the simulation parameters of the door-to-door crane transportation process under proportional scaling; Specifically, the actual gantry crane transportation process is simplified to the process of starting from no initial speed, accelerating to the maximum speed, reaching a stable speed, and then decelerating to 0m / s to the picking point.

[0040] Step 2: Based on the simulated parameters of the gantry crane transportation process under scaled conditions, the motion trajectory of the gantry crane in transporting hoisted cargo in the actual working scenario is simulated, and a control simulation model, a swing elimination model, and an anti-top impact model of the motion trajectory are constructed; Among them, the shaping algorithm is used in the control simulation model to obtain the simulated motion trajectory and the motion parameters under the time angle such as the speed of the crane and the grab; Specifically, the software simulation model is constructed using the simulink module in MATLAB according to the actual factory setting values. Step 2 specifically includes: Step 2-1, determine the target trajectory that the door-to-door crane needs to execute to transport the goods; Specifically, firstly, the task that the door-to-door crane needs to perform in transporting goods is clarified, that is, the path from the starting point to the end point; this target trajectory can be a straight line, a curve, or a path of any other shape.

[0041] Step 2-2: Based on the time required to complete the entire movement using the actual driving force obtained, define the position the system should be in at each moment and determine the speed at each position; define the change in acceleration to ensure the smoothness of the movement.

[0042] Step 2-3, set the number of continuous state variables, the number of discrete state variables, the number of outputs, and the number of inputs; Here it is assumed that there are only two input signals, representing the control input (such as the torque or force of the motor), and the direct feedthrough flag, 0 means that the output does not directly depend on the current input (that is, the output will not immediately reflect the change of the input), the number of sampling times, 0 means inheriting the default sampling time, and converting the set sizes object to a simsizes object and assigning it to sys; at the same time, the initial state vector is set, where all 6 states are initialized, and actual application needs to be adjusted according to specific circumstances.

[0043] Step 2-4: Use the shaping algorithm to smooth the acceleration changes and avoid sudden changes using cubic spline interpolation in S-curve trajectory planning.

[0044] Step 2-5: Use minimum beat control to transfer the system from one state to another in the shortest time and reduce overshoot.

[0045] Step 2-6: Perform pre-oscillation compensation before the action starts, introducing a small pre-oscillation to offset the swing caused by the subsequent action and make the model more stable.

[0046] Step 2-7: Use the PID controller to build a dynamic model of the system, including physical parameters such as mass, moment of inertia, and friction coefficient, in order to accurately predict the behavior of the system.

[0047] Step 2-8: Repeat steps 2-4 and 2-7 until the optimal trajectory algorithm result is obtained.

[0048] Step 3: Based on the simulated parameters of the portal crane transportation process under scale, the portal crane transportation model is built in combination with the size of the actual portal crane and its working scene; Specifically, according to the actual size of the portal crane, a stable base frame is built using steel structural materials. The base should be wide enough to support the weight of the entire simulation platform and ensure that it will not move during operation. A main beam is erected at the center of the base, which is the core part of the inverted T-shaped structure. The height of the main beam should be equivalent to that of the actual portal crane to ensure that its working height can be accurately simulated. A crossbeam should be installed on the top of the main beam to form a stable T-shaped structure. The connection between the crossbeam and the main beam must be firm and reliable to prevent loosening due to vibration. A lifting mechanism is installed on the main beam, usually using an electric hoist or hydraulic cylinder. The lifting mechanism should be equipped with a limit switch and an emergency brake device to ensure safe operation. At the same time, a position sensor should be installed to monitor the lifting height in real time. A walking mechanism, including a track and a running wheel, is installed under the crossbeam. The walking mechanism needs to be able to move smoothly along the main beam to simulate the process of the portal crane traveling along the dock track. The running wheel should have good wear resistance and load-bearing capacity, and an encoder should be installed to record the travel distance. A sling simulation device, such as a grab or hook, is fixed on the crossbeam. The sling simulation device should be able to rotate and tilt freely to simulate various actions under real working conditions. In addition, force sensors need to be installed to detect the interaction force between the sling and the cargo. Industrial visual cameras and sensor systems are installed to monitor the vibration, tilt and other states of the simulation platform during operation. These sensors should be installed at key locations, such as the top of the main beam, the connection of the sling, etc., to ensure that the motion information can be fully captured. Configure the control system, which mainly includes components such as the control board, motor driver, and data acquisition card. The control system is responsible for receiving data from the sensor and adjusting the motor output according to the preset control algorithm to achieve precise control of the simulation platform. At the same time, it is necessary to develop or select a suitable software interface to facilitate operators to monitor and adjust parameters. Finally, the system is debugged. First, test the functions of each subsystem (such as lifting mechanism, walking mechanism, etc.) separately, and then conduct the overall linkage test after confirmation. During this process, pay attention to whether there are abnormal noises, vibrations, etc., and adjust the relevant components in time. After debugging, a detailed user manual and maintenance guide need to be formulated to ensure the long-term stable operation of the simulation platform and the flexible configuration of other industrial lifting machine operation requirements.

[0049] Step 4: Using the trajectory control parameters obtained by the control simulation model to control the movement of the portal crane transportation model, so as to simulate the actual transportation situation of the portal crane; Specifically, the control simulation model is converted into a PLC program to control the rotation parameters of the hardware platform for testing.

[0050] Step 5: Training and verification of the anti-sway model and the anti-top-impact model; Specifically, the industrial vision camera collects images of the hoisted cargo and suspension ropes in real time, and the binocular vision system detects the length of the wire rope of the suspended load and the swing angle of the suspension rope based on the collected images.

[0051] The detected length of the wire rope for detecting the suspended load is fed back to the anti-top impact model to obtain the anti-top impact control parameters, and the movement of the gantry crane transport model is controlled based on the anti-top impact control parameters to prevent the cargo from hitting the top or the rope collection speed is too slow to collide with obstacles on the transport track.

[0052] The detected swing angle of the suspension rope is fed back to the anti-swing model to obtain the anti-swing control parameters, and the movement of the gantry crane transport model is controlled based on the anti-swing control parameters to prevent the suspension rope from swinging too much.

[0053] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An adaptive under-actuated door crane anti-sway and anti-top-impact system, characterized in that: include: Software simulation platform and hardware simulation platform; The hardware simulation platform is configured with a control system and a visual measurement module; The software simulation platform simulates the motion trajectory of transporting hoisted goods in the working scene of the real gantry crane, and constructs a control simulation model, a swing elimination model and an anti-top impact model of the motion trajectory; The hardware simulation platform builds a portal machine transportation model based on the size of the actual portal machine and its working scene; the control system controls the movement of the portal machine transportation model based on the trajectory control parameters obtained from the control simulation model built by the software simulation platform, so as to simulate the actual transportation situation of the portal machine and train and verify the anti-sway model and the anti-top impact model; The visual measurement module includes an industrial visual camera and a binocular visual system installed in a suspended safety position on the portal machine model, wherein the industrial visual camera is used to collect images of the hoisted cargo and the suspension rope, and the binocular visual system detects the length of the steel wire rope of the suspended load and the swing angle of the suspension rope based on the collected images; The training and verification of the anti-sway model and the anti-top-impact model include: The visual measurement module feeds back the detected wire rope length of the hanging load to the anti-collision model of the software simulation platform to obtain the anti-collision control parameters. The control system controls the movement of the gantry crane transport model based on the anti-collision control parameters to prevent the cargo from collide with the transport track obstacles due to the slow rope collection speed. The visual measurement module feeds back the detected swing angle of the suspension rope to the anti-swing model of the software simulation platform to obtain the anti-swing control parameters. The control system controls the movement of the gantry crane transport model based on the anti-swing control parameters to prevent the suspension rope from swinging too much.

2. The adaptive under-actuated door crane anti-sway and anti-top-impact system according to claim 1 is characterized in that: Build a door-to-door transport model, including: A proportionally scaled inverted T-shaped portal machine model is constructed; the portal machine model comprises: a base, a main beam erected at the center of the base, and a crossbeam firmly installed on the top of the main beam; Install a lifting mechanism and a position sensor for monitoring the lifting height on the main beam; A traveling mechanism is installed under the crossbeam, which can move smoothly along the main beam to simulate the process of the gantry crane traveling along the dock track; A sling simulation device is fixed on the crossbeam, and the sling simulation device can rotate and tilt freely so as to simulate various actions under real working conditions; Install force sensors to detect the interaction force between the spreader and the cargo; A sensor system for monitoring the motion status during operation is installed on the top of the main beam and at the connection of the spreader simulation device; The configuration is responsible for receiving data from the software simulation platform and adjusting the control system of the motor output according to the received data.

3. The adaptive under-actuated door crane anti-sway and anti-top-impact system according to claim 1, characterized in that: Construct a dynamic model to simulate the movement trajectory of cargo in a door-to-door crane, including: Determine the physical parameters of the portal crane transport model, including: the mass of the portal crane trolley 、 The length of the wire rope that suspends the load, the driving force of the rope to lift it, and the load swing angle; Based on the physical parameters of the portal crane transportation model, the Lagrangian method is used to establish a nonlinear dynamic model for simulating the movement trajectory of the portal crane cargo; the nonlinear dynamic model includes: the Lagrangian equations of the crossbeam component of the lifting driving force of the lifting rope, the lifting driving force of the lifting rope and the swing angle during the lifting of the cargo.

4. The adaptive under-actuated door crane anti-sway and anti-top-impact system according to claim 3 is characterized in that: Construct a swing elimination model, including: The nonlinear dynamic model of the simulated gantry crane cargo motion trajectory is analyzed in two-dimensional phase plane, and a swing elimination model based on the shaping algorithm is established under the zero initial state to obtain the relationship between the load swing angle and the crane displacement acceleration as well as the maximum and minimum values ​​of the load swing angle. Among them, the relationship between the load swing angle and the crane displacement acceleration is: ； in, is the crane displacement acceleration, For the quality of the gantry crane trolley, is the load swing angle, is the acceleration due to gravity, For the quality of goods, It is the beam force component of the lifting driving force of the rope; The maximum and minimum values ​​of the load swing angle are: ； in, is the maximum load swing angle, is the minimum load swing angle, is a constant, g is the acceleration due to gravity, is the initial value of the load swing angle, is the initial value of the load swing angular velocity; Based on the maximum and minimum values ​​of the load swing angle, a constraint condition of the load swing angle is determined; the constraint condition of the load swing angle is: the maximum and minimum values ​​of the load swing angle are respectively less than a preset angle.

5. The adaptive under-actuated door crane anti-sway and anti-top-impact system according to claim 4 is characterized in that: The visual measurement module feeds back the detected swing angle of the suspension rope to the anti-swing model of the software simulation platform to obtain anti-swing control parameters, including: Based on the swing angle of the suspension rope detected by the visual measurement module, the relationship between the load swing angle and the crane displacement acceleration is used to obtain the crane displacement acceleration and whether the current swing angle direction is in the same direction or in the opposite direction of the crane movement direction; The control system controls the movement of the portal crane transport model based on the anti-sway control parameter to prevent the suspension rope from swinging too much, including: When the load swing angle does not meet the constraint conditions, if the current swing angle direction is in the same direction as the crane movement direction, the acceleration of the crane running motor is increased; if the current swing angle direction is in the opposite direction to the crane movement direction, the acceleration of the crane running motor is reduced.

6. The adaptive under-actuated door crane anti-sway and anti-top-impact system according to claim 1, characterized in that: Construct an anti-roofing model, including: The left and right views of the cargo transported by the gate machine collected in real time by the binocular industrial vision camera in the visual measurement module are stereo corrected to obtain the internal and external parameters of the binocular industrial vision camera; the internal and external parameters of the binocular industrial vision camera include: binocular baseline distance T , Camera focal length f , the reference point in the world coordinate system with the left camera as the reference , where the coordinate Z represents the length of the wire rope that suspends the load l ; The component of the X direction in the two image coordinate systems of the point projection on the left and right image planes is , get the projection parallax of the left and right images d : ； Based on the parallax of left and right screen projection d The rope distance measurement formula is obtained: ； Calculate the rope ascent or descent distance under fixed time sampling ,speed : ； Among them, k is the change value; ； The constraints must be met: ； in, is the minimum rope speed, is the maximum rope speed.

7. The adaptive under-actuated door crane anti-sway and anti-top-impact system according to claim 6, characterized in that: The visual measurement module feeds back the detected length of the wire rope of the suspended load to the anti-top impact model of the software simulation platform to obtain the anti-top impact control parameters, including: Based on the length of the wire rope of the suspended load detected by the visual measurement module, the speed deviation is obtained. - or - ; The control system controls the movement of the portal crane transport model based on the anti-collision control parameter to prevent the cargo from collide with the transport track obstacle due to the slow rope collection speed, including: when If the constraints are not met, Greater than ,by - The speed deviation reduces the rope motion motor speed. Less than ,by - The speed deviation increases the rope motion motor speed.

8. An adaptive under-actuated door machine anti-sway and anti-top-impact method, characterized in that: The method uses an adaptive under-actuated door machine sway elimination and top impact prevention system as described in any one of claims 1 to 7 to eliminate sway and prevent top impact, and the method comprises the following steps: Step 1: Simplify the actual door-to-door crane transportation process and obtain the simulation parameters of the door-to-door crane transportation process under proportional scaling; Step 2: Based on the simulated parameters of the gantry crane transportation process under scaled conditions, the motion trajectory of the gantry crane in transporting hoisted cargo in the actual working scenario is simulated, and a control simulation model, a swing elimination model, and an anti-top impact model of the motion trajectory are constructed; Step 3: Based on the simulated parameters of the portal crane transportation process under scale, the portal crane transportation model is built in combination with the size of the actual portal crane and its working scene; Step 4: Using the trajectory control parameters obtained by the control simulation model to control the movement of the portal crane transportation model, so as to simulate the actual transportation situation of the portal crane; Step 5: Training and verification of the anti-sway model and anti-top-impact model, including: The industrial vision camera collects images of the hoisted cargo and the suspension rope in real time, and the binocular vision system detects the length of the wire rope hanging the load and the swing angle of the suspension rope based on the collected images; Feeding back the detected length of the wire rope of the hanging load to the anti-collision model to obtain the anti-collision control parameters, and controlling the movement of the gantry crane transport model based on the anti-collision control parameters to prevent the cargo from collide with the transport track obstacles due to the slow rope collection speed; Feeding back the detected swing angle of the suspension rope to the anti-swing model to obtain the anti-swing control parameter, and controlling the movement of the portal crane transport model based on the anti-swing control parameter to prevent the suspension rope from swinging too much; Step 6: Apply the trained and verified control simulation model, sway elimination model and top impact prevention model to the actual adaptive under-actuated door crane to achieve sway elimination and top impact prevention of the actual adaptive under-actuated door crane.

9. The method for preventing swing and top impact of an adaptive under-actuated door crane according to claim 8, characterized in that: Based on the simulated parameters of the gantry crane transportation process under scaled conditions, the motion trajectory of the gantry crane in transporting hoisted goods in the actual working scenario is simulated, and the control simulation model, swing elimination model and top impact prevention model of the motion trajectory are constructed, including: Determine the target trajectory that the door-to-door aircraft needs to follow to deliver the goods; Based on the time required to complete the entire movement with the actual driving force obtained, define the position the system should be in at each moment and determine the speed at each position; define the change in acceleration to ensure the smoothness of the movement; Set the number of continuous state variables, the number of discrete state variables, the number of outputs, and the number of inputs; The reference shaping algorithm uses cubic spline interpolation in S-curve trajectory planning to smooth the changes in crane motion acceleration; Use minimum beat control to transfer the system from one state to another in the shortest time and reduce overshoot; Pre-oscillation compensation is performed before the action starts, introducing a small pre-oscillation to offset the swing caused by the subsequent action and make the model more stable.

10. The method for preventing swing and top impact of an adaptive under-actuated door crane according to claim 8, characterized in that: Simplifying the actual gantry crane transportation process includes: simplifying the actual gantry crane transportation process to a process without initial speed, first accelerating to the maximum speed and then to the stable speed from the feeding location to the picking point, and then decelerating to 0m / s to the picking point.

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