Tower crane group working condition detection system for main tower construction

Abstract

The application relates to the technical field of tower cranes, and particularly discloses a tower crane group working condition detection system for main tower construction, which comprises a task allocation module, a model creation module, a field tracking module, a weight allocation module, a tower crane state monitoring module, a tower crane anti-collision module, a collision risk analysis module and a risk early warning module; the tower crane state monitoring module is used for monitoring the running state of the tower crane in real time, and monitoring data is associated to a created tower crane BIM model to display the running state of the tower crane in real time; the tower crane anti-collision module is used for acquiring tower crane parameters according to sensors on the tower crane; the collision risk analysis module is used for obtaining the collision risk level of the tower crane according to the current tower crane parameters and the collision range of the tower crane; and the risk early warning module is used for sending alarm information to the tower crane according to the collision risk level and controlling the opening and closing of a damping device. The scheme can solve the problem that the safety monitoring system of a general existing tower crane is difficult to realize comprehensive monitoring and management of the tower crane group of the whole bridge main tower construction site.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of tower cranes, in particular to a tower crane group working condition detection system for main tower construction. BACKGROUND

[0002] In the field of modern architecture, tower cranes, as indispensable large-scale construction equipment, play a crucial role in promoting urbanization and constructing high-rise buildings. With the continuous rise of city skylines, tower cranes are increasingly used, and their numbers have also surged. However, this trend is accompanied by a series of safety challenges, especially in complex and variable construction site environments, the operation and maintenance safety of tower crane groups becomes particularly prominent.

[0003] Traditional tower crane safety assurance methods mainly rely on the professional skills and experience accumulation of operators, as well as regular maintenance and inspection processes. However, this human-dependent approach has obvious shortcomings. On the one hand, operator errors or negligence can directly cause safety accidents, resulting in immeasurable consequences. On the other hand, traditional maintenance and inspection methods are difficult to achieve real-time dynamic monitoring and early warning of tower crane groups, making it difficult to capture potential safety hazards in time, and thus unable to effectively intervene at the early stage of accidents.

[0004] In order to improve the service safety of tower cranes, safety monitoring systems have been applied. These systems usually integrate load monitoring, height monitoring, amplitude monitoring, inclination monitoring and other functions, and can realize real-time monitoring and early warning of a single tower crane. However, in the safety assurance of tower crane groups, these systems still have some shortcomings. In the construction of bridges, the main tower of the bridge is as high as 200m, and as the main tower is built upwards, it is difficult for the human eye to judge the working condition of the tower arm. In addition, the main tower built between peaks has a tower bottom elevation of over 1000m, and the environment at the upper part of the tower is easily obscured by smog. At the same time, the tower cranes on the approach bridge piers are densely distributed, close in distance and numerous in number; the existing single tower crane safety monitoring system lacks comprehensive consideration of the coordinated operation and mutual influence between tower crane groups, making it difficult to achieve unified monitoring and efficient management of the entire construction site tower crane group. How to coordinate and work efficiently, and avoid interference between each other is a problem that needs to be solved by those skilled in the art. SUMMARY

[0005] The present application provides a tower crane group working condition detection system for main tower construction, to solve the problem that the general existing tower crane safety monitoring system is difficult to achieve comprehensive monitoring and management of the entire bridge main tower construction site tower crane group.

[0006] To solve the above problems, the technical scheme adopted by the present application is as follows: a tower crane group working condition detection system for main tower construction, comprising a task allocation module, a model creation module, a field tracking module, and a weight allocation module;

[0007] The field tracking module is used to obtain a monitoring picture of the construction area according to the monitoring and three-dimensional camera installed on the construction site.

[0008] The model creation module is used to obtain point cloud data from the monitoring picture of the construction area and create a BIM model of the construction area.

[0009] The task allocation module is used to obtain tower crane task information, determine a tower crane group capable of performing the task within the range of the starting point coordinates and the end point coordinates of a single tower crane task, and allocate the task to a target tower crane according to the load capacity of each tower crane in the tower crane group, the number of times of avoidance of other tower cranes when performing the task, and the length of the execution path.

[0010] The tower crane task information includes the weight of the target goods, the characteristics of the target goods, the starting point coordinates and the end point coordinates of the target goods.

[0011] The weight allocation module is used to assign different weights to four types of data, including load capacity, avoidance times, execution path, and target goods characteristics, which are used by the tower crane in task allocation, and apply the weight rules to the task allocation module.

[0012] The basic principle of the present scheme is that the staff in the main control room can observe the actual situation of the field operation in real time according to the monitoring picture and the BIM model of the construction site.

[0013] The beneficial effects of the present scheme are that different tasks are accurately allocated to each tower crane in the tower crane group by analyzing the information during task execution, ensuring that the most suitable tower crane is selected to perform the task according to the load, avoidance times, and execution path during task allocation.

[0014] Further, the tower crane state monitoring module, the tower crane anti-collision module, the collision risk analysis module, and the risk warning module are included.

[0015] The tower crane state monitoring module is configured to monitor the running state of the tower crane in real time and associate the monitoring data to the created BIM model of the tower crane to display the running state of the tower crane in real time. The running state includes normal work of the tower crane, full load of the tower crane, overload of the tower crane, amplitude exceeding the upper limit, amplitude exceeding the lower limit, inclination of the tower crane, and rotation angle of the tower crane.

[0016] The tower crane anti-collision module is configured to obtain tower crane parameters from sensors on the tower crane, including the height of the hook, the rotation angle of the hoist arm, the inclination angle of the hoist arm, the wind speed of the environment where the tower crane is located, and the position of the tower crane, and obtain the collision range between adjacent tower cranes according to the obtained tower crane parameters.

[0017] The collision risk analysis module is configured to obtain the collision risk level of the tower crane according to the current tower crane parameters and the collision range. The collision risk level includes first level, second level, and third level. When both tower cranes are within the collision range, the risk level is first level. When one of the tower cranes is within the collision range, the risk level is second level. When both tower cranes are outside the collision range, the risk level is third level.

[0018] The risk warning module is configured to send alarm information to the tower crane according to the collision risk level and control the opening and closing of the damping device, which is used to control the rotation speed of the tower crane and the pitch speed of the hoist arm.

[0019] By installing the first height sensor and the second height sensor on each tower crane in the tower crane group, the collision range between adjacent tower cranes can be calculated. The collision range is calculated by the height difference H between the hoist arm and the hook of the tower crane, with the length of the tower crane hoist arm as the radius R, to calculate the active volume range of the cylinder with the tower crane as the axis. The coordinate range of the overlapping part of the two tower crane cylinders is obtained as the collision range by intersecting the active volume ranges of the two adjacent cylinders in three-dimensional space. The collision range is displayed in the BIM model, and the boundary of the collision range is used as the trigger threshold of the collision risk level in the collision risk analysis module.

[0020] The safety monitoring system of the general existing tower crane is difficult to realize comprehensive monitoring and management of the tower crane group of the whole bridge main tower construction site, the collision range between adjacent tower cranes is calculated by combining the sensor and the collision risk analysis module, which can be applied to the mixed tower crane group of different types of existing tower cranes, even if the working modes of the luffing tower crane and the tower crane are different, the collision range between the two tower cranes can be accurately obtained, the alarm information is sent in time according to the collision risk level of the tower crane, and the rotation speed and the pitch speed of the tower crane are controlled through the damping device, so that the tower crane group can be monitored in time to avoid collision accidents.

[0021] Further, the sensor comprises a first height sensor, a second height sensor, a rotation sensor, an inclination sensor, a wind speed sensor, a high-definition camera and a millimeter wave radar.

[0022] Further, the first height sensor is installed on the hook and used for measuring the height of the hook.

[0023] The second height sensor is installed at the front end of the hoisting arm and used for measuring the height of the hoisting arm.

[0024] The rotation sensor is installed at the rotation shaft of the tower crane, takes the rotation shaft of the tower crane as a pole point, measures the polar coordinate of the hoisting arm, and is used for measuring the rotation angle of the hoisting arm.

[0025] The inclination sensor is installed at the front end of the hoisting arm, takes the horizontal state of the hoisting arm as a pole point, measures the polar coordinate of the front end of the hoisting arm, and is used for measuring the pitch angle of the hoisting arm.

[0026] The wind speed sensor is installed at the front end of the hook and used for measuring the environmental wind speed.

[0027] The high-definition camera is installed at the top of the tower crane and used for collecting image information in the working range of the tower crane.

[0028] The millimeter wave radar is installed at the front end of the hook and used for actively detecting obstacles entering the detection area, detecting the size profile and relative position of the obstacles in the working range of the tower crane, and obtaining the spatial coordinates of the obstacles.

[0029] Further, the damping device can be installed on the tower crane and the luffing tower crane, when installed on the tower crane, the damping device is located on the rotation shaft of the hoisting arm, and when installed on the luffing tower crane, the damping device is installed between the pin joint of the luffing arm and the tower body.

[0030] Further, the damping device is an eddy current damper.

[0031] Further, the risk warning module comprises an alarm and a display, the alarm is installed in the cab of the tower crane, and the display is movably installed on the front side of the seat in the cab of the tower crane, the alarm is used for playing alarm information, and the display is used for displaying a three-dimensional image of the current tower crane and the collision range.

[0032] Further, the ergonomics analysis module is further used for storing historical working information of the tower crane and displaying historical ergonomics analysis results in a chart, and the historical ergonomics analysis results comprise height change information, wind speed change information, operation mode, operator, load percentage, and information of getting on and off the machine. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 The structure block diagram of the embodiment of the application is shown. DETAILED DESCRIPTION

[0034] The following is further described in detail through specific embodiments:

[0035] The embodiment is basically as shown in the accompanying drawings: Figure 1

[0036] The tower crane group working condition detection system for main tower construction comprises a task allocation module, a model creation module, a field tracking module, a weight allocation module, a tower crane state monitoring module, a tower crane anti-collision module, a collision risk analysis module, and a risk warning module.

[0037] The field tracking module is used for obtaining a monitoring picture of a construction area according to a monitoring camera and a three-dimensional camera installed on a construction site.

[0038] The model creation module is used for obtaining point cloud data and creating a BIM model of the construction area according to the monitoring picture of the construction area.

[0039] The task allocation module is used for obtaining tower crane task information, according to the start point coordinates and the end point coordinates of a single tower crane task, a tower crane group capable of executing the tower crane task in the start point coordinate range, and according to the load amount of different tower cranes in the tower crane group, the number of times of avoiding other tower cranes when executing the task, and the length of the execution path, the task is allocated to a target tower crane. If the task exceeds the load of a single tower crane, the load is ignored to create a tower crane group, and the task is marked, and then multiple towers are selected for cooperation from the tower crane group.

[0040] Specifically, the tower crane task information comprises the weight of a target cargo, the characteristics of the target cargo, the start point coordinates and the end point coordinates of the target cargo; wherein the field tracking module is further used for identifying and classifying different target cargos according to the characteristics of the target cargos on the monitoring picture. In addition, the shape characteristics of the target cargo can be obtained by comparing the image information identified by the field tracking module in the past cargo execution process with the characteristics of the target cargo. ​

[0041] The weight distribution module is used to assign different weights to the four types of data, i.e., load quantity, avoidance times, execution path, and target cargo characteristics, which are followed by the tower crane when assigning tasks, and apply the weight rules to the task assignment module. Specifically, in the embodiment, the weight of the load quantity is 0.2, the weight of the avoidance times is 0.5, the weight of the execution path accounts for 0.2, and the weight of the characteristics of the target cargo accounts for 0.1.

[0042] By assigning different weights to the parameters followed by different task assignments, the load quantity weight: in the case where both high-load tower cranes and low-load tower cranes can execute the same task, in order to ensure that high-load tower cranes are fully utilized, high-load tower cranes are given priority in handling large-load target cargos, and high-load tower cranes are prevented from being occupied due to the completion of small-load cargo tasks, so that large-load tasks are not delayed.

[0043] The path length weight: optimizing path selection, reducing unnecessary movement, thereby saving time and resources.

[0044] The avoidance times weight: reducing avoidance actions, when a tower crane performs a task, other tower cranes on its rotation or movement path need to stop avoiding, so that the tower crane task execution is smoother, and the overall efficiency is improved.

[0045] The tower crane state monitoring module is used to monitor the running state of the tower crane in real time, and associate the monitoring data to the created tower crane BIM model to display the running state of the tower crane in real time. The running state includes normal work of the tower crane, full load of the tower crane, overload of the tower crane, amplitude exceeding the upper limit, amplitude exceeding the lower limit, inclination of the tower crane, and rotation angle of the tower crane.

[0046] Specifically, the tower crane itself is equipped with five safety limit devices, including a lifting height limiter, a torque limiter, a lifting capacity limiter, a rotation limiter, and an amplitude trolley limiter. When none of the five limit devices is triggered, the running state of the tower crane is normal work; when the torque limiter is triggered, the running state of the tower crane is overload; when the lifting capacity limiter is triggered, the tower crane is overloaded; when the amplitude trolley limiter is triggered, when the lower limit of the amplitude trolley movement range is reached, the running state of the tower crane is amplitude exceeding the lower limit, and when the upper limit of the amplitude trolley movement range is reached, the running state of the tower crane is amplitude exceeding the upper limit. The running state of each tower crane is displayed in the BIM model by the tower crane state monitoring module, thereby facilitating the staff of the command center to monitor the real-time running state of the tower crane group.

[0047] The lifting height limiter is used to prevent possible operation errors when the hook is lifted or lowered. The lifting height limiter is mostly located on the side of the balance arm winch to prevent the hook from rising beyond the limit and colliding with the arm head structure.

[0048] Moment limiter, used to limit the actual working moment of the tower crane to not exceed the rated working moment, so as to avoid the whole machine from tipping over.

[0049] Load limiter: an insurance device for preventing the crane from overloading, which can automatically cut off the power supply of the lifting mechanism to stop or issue a warning when the load exceeds the rated load.

[0050] Rotation limiter, used to prevent excessive rotation in the same direction and to prevent the main cable from being twisted off.

[0051] Amplitude limiter of luffing trolley, amplitude limiter of luffing trolley of tower crane with horizontal arm trolley, also known as trolley travel limiter switch, used to limit the movement range of the load trolley on the jib.

[0052] Tower crane anti-collision module, used to obtain tower crane parameters from sensors on the tower crane, the tower crane parameters including the height of the hook, the rotation angle of the jib, the inclination angle of the jib, the wind speed of the environment where the tower crane is located, and the position of the tower crane, and obtain the collision range between adjacent tower cranes according to the obtained tower crane parameters.

[0053] Specifically, the sensors include a first height sensor, a second height sensor, a rotation sensor, an inclination sensor, a wind speed sensor, a high-definition camera, and a millimeter wave radar.

[0054] The first height sensor is installed on the hook and used to measure the height of the hook.

[0055] The second height sensor is installed at the front end of the jib and used to measure the height of the jib; for a horizontal luffing trolley tower crane, the height data obtained by the second sensor increases step by step as the tower crane standard section is raised; for a luffing jib tower crane, the height data obtained by the second sensor dynamically changes as the luffing jib is raised and lowered during hoisting work.

[0056] The rotation sensor is installed at the tower crane rotation shaft, taking the tower crane rotation shaft as the pole point, measures the polar coordinate of the jib, and is used to measure the rotation angle of the jib; the rotation data obtained by the rotation sensor is displayed in the BIM model at the running state of the tower crane, i.e., the tower crane rotation angle.

[0057] The inclination sensor is installed at the front end of the jib, taking the horizontal state of the jib as the pole point, measures the polar coordinate of the front end of the jib, and is used to measure the inclination angle of the jib.

[0058] The wind speed sensor is installed at the front end of the hook and used to measure the environmental wind speed.

[0059] The high-definition camera is installed at the top of the tower crane and used to collect image information in the vicinity of the working range of the tower crane.

[0060] The millimeter wave radar is installed at the front end of the hook, and is used for active detection of obstacles entering the detection area, detection of the size profile and relative position of obstacles in the tower crane working range, and obtaining the spatial coordinates of the obstacles.

[0061] A collision risk analysis module is configured to obtain a collision risk level of the tower crane according to the current tower crane parameters and the collision range, and the collision risk level includes a first level, a second level and a third level. When both of the two tower cranes are located within the collision range, the risk level is the first level. When one of the two tower cranes is located within the collision range, the risk level is the second level. When both of the two tower cranes are located outside the collision range, the risk level is the third level.

[0062] Specifically, the height difference H between the hoisting arm and the hook of the tower crane, and the radius R of the tower crane hoisting arm length are used to calculate the active volume range of the cylinder with the tower crane as the axis. The coordinate range of the overlapping part of the two tower crane cylinders is obtained as the collision range by intersecting the active volume ranges of the two adjacent cylinders in three-dimensional space. The collision range is displayed in the BIM model, and the boundary of the collision range is used as the trigger threshold of the collision risk level in the collision risk analysis module.

[0063] Specifically, the radius of the active volume range is adjusted according to the environmental wind speed obtained by the wind speed sensor. When the wind speed is five, the work needs to be stopped. When the wind speed is one to four, the active radius r of the hook and the radius R of the tower crane hoisting arm are calculated. Specifically, when the wind speed is one to four, r=0.01h, r=0.02h, r=0.04h, and r=0.05h.

[0064] A risk warning module is configured to send alarm information to the tower crane according to the collision risk level, and control the opening and closing of the damping device, which is used to control the slewing speed of the tower crane and the luffing speed of the hoisting arm.

[0065] Specifically, the collision risk level includes low risk, medium risk and high risk. The low risk is that the coordinate positions of the first height sensor and the second height sensor of the two tower cranes are both outside the collision range. The medium risk is that the first height sensor or the second height sensor of one of the two tower cranes is within the collision range. The high risk is that the coordinate positions of the first height sensor or the second height sensor of the two tower cranes are within the collision range.

[0066] When the risk level is low, medium, or high, the risk warning module sends an alarm message. When the risk level is high, the risk warning module also starts a damping device. Specifically, the damping device is an eddy current damper, which can limit the rotation speed of the slewing mechanism of the tower crane and the luffing speed of the jib of the mobile tower crane. The damping device can be installed on the tower crane and the mobile tower crane. When installed on the tower crane, the damping device is located on the slewing shaft of the jib. When installed on the mobile tower crane, the damping device is installed between the jib and the pin joint of the tower body.

[0067] The risk warning module includes an alarm and a display. The alarm is installed in the cab of each tower crane, and the display is movably installed in front of the seat in the cab of the tower crane. The alarm is used to play alarm information, and the display is used to display the three-dimensional image of the current tower crane and the three-dimensional image of the tower crane in the vicinity of the collision range. Specifically, the digital twin image of the tower crane can be constructed using the coordinates of the first height sensor and the second height sensor of each tower crane.

[0068] The ergonomics analysis module is also included. The ergonomics analysis module is used to store historical working information of the tower crane and display historical ergonomics analysis results through charts. The historical ergonomics analysis results include height change information, wind speed change information, operation mode, operator, load percentage, and information about getting on and off the machine.

[0069] The above is only an embodiment of the present application, and common knowledge about specific structures and characteristics in the scheme is not described in detail. It should be noted that for those skilled in the art, without departing from the structure of the present application, a number of modifications and improvements can be made, which should be considered as the protection scope of the present application. The protection scope of the present application should be subject to the content of its claims, and the specific implementation manner in the specification can be used to explain the content of the claims.

Claims

1. A tower crane group working condition detection system for main tower construction, characterized in that: The task allocation module, the model creation module, the field tracking module, and the weight allocation module are included. The field tracking module is configured to acquire a monitoring picture of a construction area according to monitoring and a three-dimensional camera installed on a construction site. The model creation module is configured to acquire point cloud data according to the monitoring picture of the construction area and create a BIM model of the construction area. The task allocation module is configured to acquire tower crane task information, determine a tower crane group capable of performing a task in a range of a starting point coordinate and an ending point coordinate of a single tower crane task according to the starting point coordinate and the ending point coordinate, and allocate the task to a target tower crane according to a load amount of each tower crane in the tower crane group, avoidance times of other tower cranes when the task is performed, and lengths of execution paths. The tower crane task information includes a weight of a target cargo, a feature of the target cargo, a starting point coordinate of the target cargo, and an ending point coordinate of the target cargo. The field tracking module is further configured to classify the target cargo according to a cargo picture feature of a completed task and estimate a weight feature of the target cargo according to the classification of the target cargo. The weight allocation module is configured to assign different weights to four types of data, including a load amount, avoidance times, an execution path, and a target cargo feature, on which the tower crane relies when the task is allocated, and apply the weight rule to the task allocation module. The tower crane state monitoring module, the tower crane anti-collision module, the collision risk analysis module, and the risk warning module are further included. The tower crane state monitoring module is configured to monitor a running state of the tower crane in real time and associate monitoring data to the created tower crane BIM model to display the running state of the tower crane in real time. The running state includes normal work of the tower crane, full load of the tower crane, overload of the tower crane, amplitude exceeding an upper limit, amplitude exceeding a lower limit, inclination of the tower crane, and rotation angle of the tower crane. The tower crane anti-collision module is configured to acquire tower crane parameters according to sensors on the tower crane, the tower crane parameters including a height of a hook, a rotation angle of a hoist arm, an inclination angle of the hoist arm, a wind speed of an environment in which the tower crane is located, and a position of the tower crane, and obtain a collision range between adjacent tower cranes according to the obtained tower crane parameters.

2. The tower crane group working condition detection system for main tower construction according to claim 1, characterized in that: The collision risk analysis module is configured to obtain a collision risk level of the tower crane according to the current tower crane parameters and the collision range, the collision risk level including a first level, a second level, and a third level.

3. The tower crane group working condition detection system for main tower construction according to claim 2, characterized in that: When both of the two tower cranes are located in the collision range, the risk level is the first level. When one of the two tower cranes is located in the collision range, the risk level is the second level. When both of the two tower cranes are located outside the collision range, the risk level is the third level. The risk warning module is configured to send alarm information to the tower crane according to the collision risk level and control opening and closing of a damping device for controlling a rotation speed of the tower crane and a tilting speed of the hoist arm. The sensors include a first height sensor, a second height sensor, a rotation sensor, an inclination sensor, a wind speed sensor, a high-definition camera, and a millimeter wave radar. The first height sensor is installed on the hook to measure the height of the hook. The second height sensor is installed at a front end of the hoist arm to measure the height of the hoist arm. The rotation sensor is installed at a tower crane rotation shaft to measure a polar angle coordinate of the hoist arm and measure the rotation angle of the hoist arm. The inclination sensor is installed at the front end of the jib, and measures the polar angle coordinate of the front end of the jib in the horizontal state of the jib as a pole, and is used for measuring the inclination angle of the jib; The wind speed sensor is installed at the front end of the hook, and is used for measuring the environmental wind speed; The high-definition camera is installed at the top of the tower crane, and is used for collecting image information near the working range of the tower crane; The millimeter wave radar is installed at the front end of the hook, and is used for actively detecting obstacles entering the detection area, detecting the size profile and relative position of the obstacles in the working range of the tower crane, and obtaining the spatial coordinates of the obstacles.

4. The tower crane group working condition detection system for main tower construction according to claim 3, characterized in that: The damping device is installed on the tower crane and the jib crane, and when installed on the tower crane, the damping device is located on the rotation shaft of the jib; when installed on the jib crane, the damping device is installed between the pin joint of the jib and the tower body.

5. The tower crane group working condition detection system for main tower construction according to claim 4, characterized in that: The damping device is an eddy current damper.

6. The tower crane group working condition detection system for main tower construction according to claim 5, characterized in that: The risk early warning module includes an alarm and a display, the alarm is installed in the cab of the tower crane, and the display is movably installed on the front side of the seat in the cab of the tower crane, the alarm is used for playing alarm information, and the display is used for displaying the three-dimensional image of the current tower crane and the collision range.

7. The tower crane group working condition detection system for main tower construction according to claim 6, characterized in that: Further comprising an ergonomics analysis module, the ergonomics analysis module is used for storing historical working information of the tower crane, and displaying historical ergonomics analysis results through charts, the historical ergonomics analysis results include height change information, wind speed change information, running mode, operator, load percentage, and information of getting on and off the machine.

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