Multi-linkage self-adaptive safety protection control system for crane and method of multi-linkage self-adaptive safety protection control system

Abstract

The invention relates to a multi-linkage self-adaptive safety protection control system and method for a crane, and the system comprises a PLC, and a forward obstacle detection unit, a reverse obstacle detection unit, a cart travel mechanism encoder, a trolley travel mechanism encoder and a height gauge detection receiving device which are connected with the PLC, the height gauge detection receiving device is connected with the height gauge detection transmitting device; the height gauge detection transmitting device comprises a rolling door height detection device located at the position of a workshop rolling door, the rolling door height detection device is connected with the transmitting device, and the transmitting device is in wireless connection with the height gauge detection receiving device. The invention has the following beneficial effects: 1, area protection can be implemented near the rolling-up door, and the crane cannot pass through the rolling-up door under the condition that the crane does not have safe passing conditions; 2, the lifting state of the rolling-up door is detected in real time, the distance between the lifting door and the rolling-up door can be pre-judged so that the crane can be decelerated firstly, and if regional protection fails, the crane can be stopped emergently so as to be prevented from colliding with the rolling-up door;

Description

Technical Field

[0001] The invention belongs to the field of crane electrical control, and in particular relates to a crane multi-interlocking adaptive safety protection control system and a method thereof. Background Art

[0002] Large-tonnage cranes are special operation equipment, mostly used for material handling in the industrial field. The working distance of the crane is several hundred meters. Different working areas are set up in the factory, and rolling doors are installed at the entrance and exit of each area. During the operation of the crane, there is a situation where the rolling door does not fully rise to the safe height and collides with the crane. How to safely, effectively and reliably ensure the safety interlock between the crane and the rolling door is one of the important issues to ensure safe production in the workshop.

[0003] For the electronic control system of old cranes, the operator can only rely on manual intervention by observing the lifting status of the rolling door in the crane's travel path during the operation of the crane to avoid collision between the crane and obstacles. This method requires the operator to maintain a high level of attention, but cannot guarantee 100% safety during the operation of the crane. Summary of the invention

[0004] The technical problem to be solved by the present invention is: how to improve the safety of the crane operation process, and the present invention provides a multiple interlocking safety protection control method.

[0005] To solve the above problems, the present invention is achieved through the following technical solutions: A crane multi-interlocking adaptive safety protection control system comprises a PLC and a forward obstacle detection unit, a reverse obstacle detection unit, a trolley running mechanism encoder, a small trolley running mechanism encoder and an altimeter detection receiving device connected to the PLC, wherein the altimeter detection receiving device is connected to an altimeter detection transmitting device; the altimeter detection transmitting device comprises a rolling door height detection device located at a workshop rolling door, the rolling door height detection device is connected to a transmitting device, and the transmitting device is wirelessly connected to the altimeter detection receiving device.

[0006] The rolling door height detection device is a diffuse reflection sensor. The sensor is located at the "workshop rolling door", which means that the sensor is located on the track of the crane trolley's running direction; and the installation height of the rolling door height detection device must be lower than the highest lifting position of the rolling door and higher than the minimum height allowed for the crane to pass.

[0007] The PLC includes a PLC processing unit, the PLC processing unit is connected to a PLC substation module, and the PLC substation module is connected to a PLC input module A02; the PLC processing unit is connected to a trolley running mechanism encoder, a small car running mechanism encoder, a switch, an altimeter detection receiving device, a forward obstacle detection unit and a reverse obstacle detection unit.

[0008] The forward obstacle detection unit includes a trolley forward running detection deceleration normally closed contact and a trolley forward running detection stop normally closed contact connected to the input end of the PLC processing unit, wherein the trolley forward running detection deceleration normally closed contact is connected to the trolley forward running deceleration relay, and the trolley forward running detection deceleration normally open contact is connected to the PLC input module; the trolley forward running detection stop normally closed contact is connected to the trolley forward running stop relay, and the trolley forward running stop normally open contact is connected to the PLC input module; The reverse obstacle detection unit includes a normally closed contact for detecting and decelerating the reverse operation of a trolley and a normally closed contact for detecting and stopping the reverse operation of a trolley, which are connected to the input end of the PLC processing unit. The normally closed contact for detecting and decelerating the reverse operation of a trolley is connected to the reverse operation deceleration relay of the trolley, and the normally open contact for detecting and decelerating the reverse operation of a trolley is connected to the PLC input module; the normally closed contact for detecting and stopping the reverse operation of a trolley is connected to the reverse operation stop relay of the trolley, and the normally open contact for detecting and stopping the reverse operation of a trolley is connected to the PLC input module.

[0009] A height detection relay is provided in the altimeter detection receiving device, and a normally open contact of the height detection relay is connected to a PLC input module.

[0010] A crane multi-linkage adaptive safety protection control method using the system comprises the following control steps: Step 1: Equip the crane with a trolley running mechanism encoder and a trolley running mechanism encoder. The trolley running mechanism encoder and the trolley running mechanism encoder calculate the trolley running and trolley running positions in real time. If the crane's PLC does not receive any passable signal, the crane will not be able to pass through the rolling door and can only run near the rolling door. Step 2: PLC determines whether the current running position of the trolley and the car is greater than 10 meters from the rolling door. At the same time, the height meter detection transmitter detects the height of the rolling door in real time. When the distance is greater than 10 meters, PLC continues to detect and judge. When the distance is less than 10 meters and the rolling door is not raised to a safe height, the rolling door height detection sensor will detect the rolling door in front of the crane, and PLC uses the forward obstacle detection unit and the reverse obstacle detection unit to slow down the crane. Step 3: PLC determines whether the current running position of the trolley and the car is greater than 2 meters from the rolling door position. At the same time, the height meter detection transmitter detects the height of the rolling door in real time. When the distance is greater than 2 meters, execute step 2. When it is less than 2 meters and the rolling door is not raised to a safe height, the rolling door height detection sensor will detect the rolling door in front of the crane, and PLC uses the forward obstacle detection unit and the reverse obstacle detection unit to stop the crane. Step 4: After the altimeter detection transmitter detects that the rolling door has been lifted to a safe height, the rolling door height detection sensor cannot detect the rolling door in front, indicating that the rolling door has been lifted to a height that allows the crane to pass safely, and the crane can pass the rolling door safely.

[0011] The transmission signal of the height meter detection transmitting device is a continuous signal, that is, the height detection relay is continuously energized, then the normally open contact of the height detection relay is closed, and the PLC input module is continuously fed back with a feedback signal to ensure that the crane PLC can safely receive the signal status. When the feedback signal is interrupted, the height meter detection receiving device installed on the crane will immediately be unable to receive the signal. When the signal is interrupted, the PLC controls the forward obstacle detection unit and the reverse obstacle detection unit, and the crane is not allowed to pass through the rolling door.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. Area protection can be implemented near the rolling door. If the crane does not have the conditions for safe passage, it cannot pass through the rolling door; 2. Real-time detection of the lifting status of the rolling door can predict the distance to the rolling door and slow down the crane first. If the area protection fails, the crane can be stopped urgently to avoid collision with the rolling door. 3. The lifting height information of the rolling door is interconnected with the crane position information in real time, and the area protection can be released online; 4. When the rolling door is closed or lifted, the crane can still work near the rolling door. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a topological structure diagram of the present invention; Figure 2 is a control circuit diagram of the present invention; Figure 3 It is a control flow chart of the present invention. DETAILED DESCRIPTION

[0014] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions 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 are within the scope of protection of the present invention.

[0015] In the description of the present invention, it is necessary to understand that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0016] like Figure 1 — Figure 3 As shown, a crane multi-interlocking adaptive safety protection control system includes a PLC and a forward obstacle detection unit, a reverse obstacle detection unit, a trolley running mechanism encoder, a small car running mechanism encoder and an altimeter detection receiving device connected to the PLC, wherein the altimeter detection receiving device is connected to the altimeter detection transmitting device; the altimeter detection transmitting device includes a rolling door height detection device located at the workshop rolling door, the rolling door height detection device is connected to the transmitting device, and the transmitting device is wirelessly connected to the altimeter detection receiving device.

[0017] The rolling door height detection device is a diffuse reflection sensor. The sensor is located at the "workshop rolling door" means that the sensor is located on the track of the crane trolley running direction (bidirectional). Therefore, the sensor can be located on the trolley running track, and can be 10 meters away from the rolling door (adjustable). It has an adjustable detection distance and dual-point output. The installation height of the rolling door height detection device should be lower than the highest lifting position of the rolling door and higher than the minimum height allowed for the crane to pass.

[0018] When the rolling door is not raised to a safe height, the forward obstacle detection unit will detect the rolling door in front of the crane. At this time, the crane will slow down at a distance of 10 meters (adjustable) from the rolling door to avoid failure of the area protection during operation. The crane will stop at 2 meters (adjustable) to avoid accidental collision.

[0019] When the rolling door is raised to a safe height, the forward obstacle detection unit cannot detect the rolling door in front, indicating that the rolling door has been raised to a height that allows the crane to pass safely. At this time, the crane can theoretically pass through the rolling door safely.

[0020] like Figure 2As shown, the PLC includes a PLC processing unit A00, which is connected to a PLC substation module A01, which is connected to a PLC input module A02; the PLC processing unit A00 is connected to a trolley running mechanism encoder, a trolley running mechanism encoder, a switch, a height meter detection receiving device, a forward obstacle detection unit, and a reverse obstacle detection unit. In this system structure, the PLC processing unit A00, the PLC substation module A01, and the PLC input module A02 are mainly used for data processing; the trolley running mechanism encoder and the trolley running mechanism encoder are used to realize the position positioning of the trolley and the trolley, and realize regional protection; the switch is used to expand the interface; the forward obstacle detection unit and the reverse obstacle detection unit are used for deceleration and stopping of the crane; the height meter detection receiving device is used to receive the height status information of the rolling door; and the above devices are all installed on the crane. The height meter detection transmitting device is used to detect the lifting height of the rolling door, and feedback the status of the rolling door to the height meter detection receiving device, and is installed at the rolling door of the workshop.

[0021] The forward obstacle detection unit 12-A02 includes a trolley forward running detection deceleration normally closed contact K03-2 and a trolley forward running detection stop normally closed contact K04-2 connected to the input end of the PLC processing unit A00. The trolley forward running detection deceleration normally closed contact K03-2 and the trolley forward running detection stop normally closed contact K04-2 are both located inside the forward obstacle detection unit 12-A02; wherein, the trolley forward running detection deceleration normally closed contact K03-2 is connected to the trolley forward running deceleration relay K03, and the trolley forward running detection deceleration normally open contact K03-1 is connected to the PLC input module A02; the trolley forward running detection stop normally closed contact K04-2 is connected to the trolley forward running stop relay K04, and the trolley forward running stop normally open contact K04-1 is connected to the PLC input module A02. In this way, when the rolling door height detection device detects the distance to the obstacle, for example, after 10 meters, the state of the normally closed contact K03-2 for the forward running detection deceleration of the trolley changes, and after 2 meters, the state of the normally closed contact K04-2 for the forward running detection stop of the trolley changes. In this way, the corresponding state of the trolley forward running deceleration relay K03 or the trolley forward running stop relay K04 changes, thereby changing the state of the normally open contact K03-1 for the forward running detection deceleration or the normally open contact K04-1 for the forward running stop of the trolley, and the PLC input module A02 receives the feedback signal.

[0022] The PLC processing unit A00 receives the corresponding status changes and outputs instructions to make the crane slow down in the forward or reverse direction. At the same time, the trolley running mechanism encoder and the car running mechanism encoder send the actual position of the crane to the PLC processing unit and compare it with the area protection position set in the system. When the system area protection fails, the obstacle forward or reverse detection unit detects that the distance to the obstacle is less than 2 meters, and transmits the action signal to the PLC processing unit. The PLC processing unit outputs an emergency stop command to stop the crane.

[0023] The reverse obstacle detection unit 12-A01 includes a trolley reverse operation detection deceleration normally closed contact K01-2 and a trolley reverse operation detection stop normally closed contact K02-2 connected to the input end of the PLC processing unit A00. The trolley reverse operation detection deceleration normally closed contact K01-2 and the trolley reverse operation detection stop normally closed contact K02-2 are both located inside the reverse obstacle detection unit 12-A01; wherein, the trolley reverse operation detection deceleration normally closed contact K01-2 is connected to the trolley reverse operation deceleration relay K01, and the trolley reverse operation detection deceleration normally open contact K01-1 is connected to the PLC input module A02; the trolley reverse operation detection stop normally closed contact K02-2 is connected to the trolley reverse operation stop relay K02, and the trolley reverse operation stop normally open contact K02-1 is connected to the PLC input module A02. In this way, when the rolling door height detection device detects the distance to the obstacle, for example, after 10 meters, the state of the normally closed contact K01-2 for detecting deceleration when the trolley runs in reverse changes, and after 2 meters, the state of the normally closed contact K02-2 for detecting and stopping the trolley runs in reverse changes. In this way, the state of the corresponding trolley reverse running deceleration relay K01 or the trolley reverse running stop relay K02 changes, thereby changing the state of the normally closed contact K01-2 for detecting deceleration when the trolley runs in reverse or the normally closed contact K02-2 for detecting and stopping the trolley runs in reverse, and the PLC input module A02 receives the feedback signal.

[0024] It should be noted that the area protection system also includes trolley operation monitoring. The trolley operation mechanism encoder communicates with the PLC in real time, and transmits the trolley position information to the PLC to determine whether the trolley is at the origin. If it is not at the origin, the crane trolley will stop running. The trolley needs to be manually adjusted to the origin position, and the crane trolley mechanism resumes working to meet the conditions for the crane to pass through the rolling door normally to avoid collision.

[0025] A height detection relay K05 is provided in the altimeter detection receiving device, and a normally open contact K05-1 of the height detection relay is connected to a PLC input module A02.

[0026] like Figure 3 As shown, a crane multi-link adaptive safety protection control method includes the following control steps: Step 1: Configure the trolley running mechanism encoder and the trolley running mechanism encoder on the crane. The trolley running mechanism encoder and the trolley running mechanism encoder calculate the trolley running and trolley running positions in real time to set up area protection at the round trip of the rolling door. When the crane's PLC does not receive any passable signal, the crane will not be able to pass through the rolling door and can only run near the rolling door.

[0027] Step 2: PLC determines whether the current running position of the trolley and the car is greater than 10 meters from the rolling door. At the same time, the altimeter detection and transmitting device detects the height of the rolling door in real time. When the distance is greater than 10 meters, PLC continues to detect and judge. When the distance is less than 10 meters and the rolling door has not been raised to a safe height, the forward obstacle detection unit and the reverse obstacle detection unit will detect the rolling door in front of the crane. PLC uses the forward obstacle detection unit and the reverse obstacle detection unit to slow down the crane to avoid failure of the area protection during operation. Step 3: PLC determines whether the current running position of the trolley and the car is greater than 2 meters from the position of the rolling door. At the same time, the altimeter detection and transmitting device detects the height of the rolling door in real time; when the distance is greater than 2 meters, execute step 2; when it is less than 2 meters and the rolling door has not been raised to a safe height, the forward obstacle detection unit and the reverse obstacle detection unit detect the rolling door in front of the crane. PLC uses the forward obstacle detection unit and the reverse obstacle detection unit to stop the crane, so that the crane stops at 2 meters (adjustable) to avoid accidental collision.

[0028] Step 4: After the altimeter detection transmitter detects that the rolling door has been lifted to a safe height, the rolling door height detection sensor cannot detect the rolling door in front, indicating that the rolling door has been lifted to a height that allows the crane to pass safely. In theory, the crane can now pass the rolling door safely.

[0029] The working principle of the present invention is: In order to ensure the safety between the crane and the rolling door, it is only necessary to manually judge whether the crane can pass through, which has low reliability.

[0030] A height meter detection transmitter is configured at the rolling door to detect whether the rolling door has been lifted to the highest position. The transmission signal of this height meter detection transmitter is a continuous signal, that is, the height detection relay K05 is continuously energized, and the normally open contact K05-1 of the height detection relay is closed, and the PLC input module A02 is continuously fed back with a feedback signal to ensure that the crane PLC can safely receive the signal status. When the feedback signal is interrupted, the height meter detection receiving device installed on the crane will also be unable to receive the signal immediately. When the signal is interrupted, the PLC immediately outputs a command to stop the crane from working, and the crane is not allowed to pass through the rolling door.

[0031] When the feedback signal is normal, the altimeter detection transmitter is used to detect the lifting height of the rolling door. When the altimeter detection transmitter detects that the rolling door has been lifted to the highest position, its transmitter sends a confirmation signal to the altimeter detection receiver on the crane. After the PLC processes the signal, it releases the area protection. After double detection, it determines that the rolling door has reached a safe height and the crane can pass through the rolling door.

[0032] The above is only a preferred embodiment of the present invention. It should be pointed out that for those skilled in the art, several changes and improvements can be made without departing from the overall concept of the present invention, which should also be regarded as the scope of protection of the present invention.

Claims

1. A crane multi-interlocking adaptive safety protection control system, characterized in that: It includes a PLC and a forward obstacle detection unit, a reverse obstacle detection unit, a trolley running mechanism encoder, a small car running mechanism encoder and an altimeter detection receiving device connected to the PLC, wherein the altimeter detection receiving device is connected to the altimeter detection transmitting device; the altimeter detection transmitting device includes a rolling door height detection device located at the workshop rolling door, the rolling door height detection device is connected to the transmitting device, and the transmitting device is wirelessly connected to the altimeter detection receiving device.

2. A crane multi-interlocking adaptive safety protection control system according to claim 1, characterized in that: The rolling door height detection device is a diffuse reflection sensor. The sensor is located at the "workshop rolling door", which means that the sensor is located on the track of the crane trolley's running direction; and the installation height of the rolling door height detection device must be lower than the highest lifting position of the rolling door and higher than the minimum height allowed for the crane to pass.

3. A crane multi-interlocking adaptive safety protection control system according to claim 1, characterized in that: The PLC comprises a PLC processing unit (A00), the PLC processing unit (A00) is connected to a PLC substation module (A01), and the PLC substation module (A01) is connected to a PLC input module (A02); the PLC processing unit (A00) is connected to a trolley running mechanism encoder, a trolley running mechanism encoder, a switch, an altimeter detection receiving device, a forward obstacle detection unit and a reverse obstacle detection unit.

4. A crane multi-interlocking adaptive safety protection control system according to claim 3, characterized in that: The forward obstacle detection unit comprises a trolley forward running detection deceleration normally closed contact (K03-2) and a trolley forward running detection stop normally closed contact (K04-2) connected to the input end of the PLC processing unit (A00), wherein the trolley forward running detection deceleration normally closed contact (K03-2) is connected to the trolley forward running deceleration relay (K03), and the trolley forward running detection deceleration normally open contact (K03-1) is connected to the PLC input module (A02); the trolley forward running detection stop normally closed contact (K04-2) is connected to the trolley forward running stop relay (K04), and the trolley forward running stop normally open contact (K04-1) is connected to the PLC input module (A02); The reverse obstacle detection unit comprises a trolley reverse running detection deceleration normally closed contact (K01-2) and a trolley reverse running detection stop normally closed contact (K02-2) connected to the input end of the PLC processing unit (A00), wherein the trolley reverse running detection deceleration normally closed contact (K01-2) is connected to the trolley reverse running deceleration relay (K01), and the trolley reverse running detection deceleration normally open contact (K01-1) is connected to the PLC input module (A02); the trolley reverse running detection stop normally closed contact (K02-2) is connected to the trolley reverse running stop relay (K02), and the trolley reverse running stop normally open contact (K02-1) is connected to the PLC input module (A02).

5. The crane multi-interlocking adaptive safety protection control system according to claim 1 is characterized by: A height detection relay (K05) is provided in the altimeter detection receiving device, and a normally open contact (K05-1) of the height detection relay is connected to a PLC input module (A02).

6. A crane multi-interlocking adaptive safety protection control method using the system described in any one of claims 1 to 5, characterized in that: The control steps include: Step 1: Equip the crane with a trolley running mechanism encoder and a trolley running mechanism encoder. The trolley running mechanism encoder and the trolley running mechanism encoder calculate the trolley running and trolley running positions in real time. If the crane's PLC does not receive any passable signal, the crane will not be able to pass through the rolling door and can only run near the rolling door. Step 2: PLC determines whether the current running position of the trolley and the car is greater than 10 meters from the rolling door. At the same time, the height meter detection transmitter detects the height of the rolling door in real time. When the distance is greater than 10 meters, PLC continues to detect and judge. When the distance is less than 10 meters and the rolling door is not raised to a safe height, the rolling door height detection sensor will detect the rolling door in front of the crane, and PLC uses the forward obstacle detection unit and the reverse obstacle detection unit to slow down the crane. Step 3: PLC determines whether the current running position of the trolley and the car is greater than 2 meters from the rolling door position. At the same time, the height meter detection transmitter detects the height of the rolling door in real time. When the distance is greater than 2 meters, execute step 2. When it is less than 2 meters and the rolling door is not raised to a safe height, the rolling door height detection sensor will detect the rolling door in front of the crane, and PLC uses the forward obstacle detection unit and the reverse obstacle detection unit to stop the crane. Step 4: After the altimeter detection transmitter detects that the rolling door has been lifted to a safe height, the rolling door height detection sensor cannot detect the rolling door in front, indicating that the rolling door has been lifted to a height that allows the crane to pass safely, and the crane can pass the rolling door safely.

7. The crane multi-interlocking adaptive safety protection control method according to claim 6 is characterized in that: The transmission signal of the height meter detection transmitting device is a continuous signal, that is, the height detection relay (K05) is continuously energized, and the normally open contact (K05-1) of the height detection relay is closed, and the PLC input module (A02) is continuously fed back with a feedback signal to ensure that the crane PLC can safely receive the signal status. When the feedback signal is interrupted, the height meter detection receiving device installed on the crane will immediately be unable to receive the signal. When the signal is interrupted, the PLC controls the forward obstacle detection unit and the reverse obstacle detection unit, and the crane is not allowed to pass through the rolling door.

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