Early warning system and method for hoisting operation area of bridge crane

Abstract

The invention belongs to the technical field of bridge cranes, and particularly relates to an early warning system and method for a hoisting operation area of a bridge crane. According to the technical scheme, the early warning system for the hoisting operation area of the bridge crane comprises a main beam frame, a track is arranged on the main beam frame, a running trolley is installed on the track, a lifting hook is installed on the lower side of the running trolley, and the lifting hook is connected with a heavy object through a rope; a multi-line laser radar and a camera are installed on the lower side of the main beam frame, a matrix projection lamp is installed on the lower side of the running trolley, and the matrix projection lamp projects an early warning area on the ground. The invention provides an early warning system and method for a hoisting operation area of a bridge crane.

Description

Technical Field

[0001] The present invention belongs to the technical field of bridge cranes, and particularly relates to a warning system and method for the hoisting operation area of a bridge crane. Background Art

[0002] In the current hoisting operation of bridge cranes, due to the lack of real-time accurate monitoring and warning of the size, spatial position of the hoisted heavy object, and personnel and objects in the operation area, when hoisting heavy objects, the conventional method is to set a safety line around the operation and arrange a hoisting commander to observe the surrounding environment in real time. The hoisting commander needs to clear irrelevant personnel and objects on the crane operation path in advance to ensure the safety of the hoisting operation. Once the hoisting commander is negligent or makes a wrong estimate of the hoisting operation area, it is easy to cause safety accidents. When the traditional technology obtains the spatial parameters of heavy objects, the timeliness and accuracy are poor, it is difficult to determine a reasonable warning area according to the actual working conditions, and it is impossible to effectively ensure the safety of personnel and equipment at the operation site. Therefore, there is an urgent need for an innovative solution to fill the technical gap. Summary of the Invention

[0003] In order to solve the above problems existing in the prior art, the purpose of the present invention is to provide a warning system and method for the hoisting operation area of a bridge crane.

[0004] The technical solution adopted by the present invention is as follows:

[0005] A warning system for the hoisting operation area of a bridge crane includes a main beam frame. There are tracks arranged on the main beam frame, and a running trolley is installed on the tracks. A hook is installed under the running trolley, and the hook is connected to a heavy object through a rope; a multi-line lidar and a camera are respectively installed under the main beam frame, and a matrix projection lamp is installed under the running trolley, and the matrix projection lamp projects a warning area on the ground.

[0006] As a preferred solution of the present invention, a projection lamp cloud platform is installed under the running trolley, and the matrix projection lamp is installed under the running trolley through the projection lamp cloud platform.

[0007] Deploy multi-line lidars at both ends of the main beam frame of the bridge crane to accurately scan the size of the hoisted heavy object in real time. At an appropriate position of the running trolley above the hook of the bridge crane, install a projection lamp cloud platform and a matrix projection lamp, and accurately project a warning area under the heavy object according to the size of the heavy object obtained by scanning and the established safe distance for hoisting operations. With the camera, monitor the status of personnel and objects in the warning area in real time. Once it detects that a person or an object illegally enters the warning area, the warning system for the hoisting operation of the bridge crane issues an alarm, and when necessary, executes a shutdown control instruction on the bridge crane to avoid safety accidents.

[0008] As a preferred solution of the present invention, it further includes a warning system, and the multi-line lidar, the camera, the projection lamp cloud platform and the matrix projection lamp are all electrically connected to the warning system.

[0009] As a preferred embodiment of the present invention, during the rotation of the projection lamp cloud platform, there is no interference with the crane. The projection lamp cloud platform is installed at a suitable position on the traveling trolley above the hook of the bridge crane. During the rotation of the projection lamp cloud platform, there is no interference with the crane, and at the same time, the key area below the heavy object can be clearly observed. The matrix projection lamp is installed on the projection lamp cloud platform, and the projection angle of the matrix projection lamp is accurately adjusted according to the control instruction. The cable is laid to connect the matrix projection lamp and the projection lamp cloud platform to the warning system, so that it can project a specific area that meets the safety warning requirements below the heavy object according to the control instruction.

[0010] As a preferred embodiment of the present invention, the multi-line lidar is installed at both ends of the main beam frame. The multi-line lidar is installed at a suitable position with a wide view and stability at both ends of the main beam frame of the bridge crane to ensure that the scanning direction of the multi-line lidar can comprehensively and without dead angle cover the operation area of the hoisted heavy object. The cable is laid to connect the scanning data of the multi-line lidar to the warning system, providing basic data support for subsequent operation analysis.

[0011] As a preferred embodiment of the present invention, the shooting range of the camera fully covers the warning area. On the bridge crane, select the best position that can clearly shoot the warning area projected below the heavy object to install the camera, and the shooting range of the camera should fully cover the warning area. The cable is laid to connect the camera to the warning system to realize the real-time and stable transmission of the image data in the warning area, providing a data source for subsequent image recognition and analysis.

[0012] The warning method for the hoisting operation area of the bridge crane includes the following steps:

[0013] S1: Heavy object size scanning:

[0014] After the bridge crane is powered on, the multi-line lidar is immediately automatically turned on; when the hoisting mechanism starts to operate, the multi-line lidar performs an all-round scan on the hook or the heavy object to obtain the accurate size data of the heavy object, and transmits the data to the warning system;

[0015] S2: Spatial position recognition:

[0016] Including point cloud data preprocessing, feature extraction, coordinate transformation, and dynamic tracking;

[0017] S3: Determine the warning area coordinates:

[0018] The height encoder of the bridge crane measures the height of the heavy object in real time. The warning system calculates the coordinates of the required projected warning area range in the global coordinate system of the bridge crane in real time according to the regulations of the safe distance for hoisting operations at different heights, combined with the heavy object size data and the accurate position of the heavy object in space;

[0019] S4: Projection warning area:

[0020] Taking the installation point of the traveling encoder on the trolley of the bridge crane as the origin, establish a matrix projection lamp coordinate system to determine the precise coordinates of the matrix projection lamp;

[0021] During the operation of the trolley, the traveling encoder measures the distance deviation between the origin of the matrix projection lamp coordinate system and the origin of the global coordinate system of the bridge crane in real time. Through calculation, the coordinate transformation of the matrix projection lamp to the global coordinate system of the bridge crane is realized;

[0022] The warning system transmits the calculated warning area coordinates to the projection lamp pan-tilt and the matrix projection lamp; the projection lamp pan-tilt and the matrix projection lamp are adjusted to the appropriate angles according to the coordinate information, and corresponding red lights are projected below the heavy object to calibrate the warning area;

[0023] S5: Real-time monitoring and warning:

[0024] The camera captures the images in the warning area in real time, and the warning system judges whether there are people or objects in the warning area through image recognition.

[0025] As a preferred solution of the present invention, step S2 is specifically:

[0026] Point cloud data preprocessing and feature extraction: Preprocess the original point cloud data obtained by the multi-line lidar and perform feature extraction to provide basic data for subsequent precise coordinate transformation;

[0027] Coordinate transformation: Taking a fixed point of the bridge crane as the origin, establish a global coordinate system of the bridge crane; taking the installation center of the multi-line lidar as the origin, establish a lidar coordinate system; select several fixed points of the bridge crane as calibration objects, and determine the coordinates (x 1i , y 1i , z 1i ) of the calibration objects in the global coordinate system of the bridge crane through measurement and the crane design drawings; where i = 1, 2,..., n, and n is the number of calibration objects; the multi-line lidar scans the calibration objects to obtain the coordinates (x 2i , y 2i , z 2i ) of the calibration objects in the lidar coordinate system; construct a mathematical model to realize the transformation of the lidar coordinate system to the global coordinate system of the bridge crane, and obtain the precise position data of the heavy object in the working space;

[0028] Dynamic tracking: Calculate the position at the current moment according to the position and speed of the heavy object at the previous moment, and correct it in combination with the real-time measurement data of the multi-line lidar, continuously optimize the predicted value of the position of the heavy object, and track the position change of the heavy object during the lifting process in real time.

[0029] As a preferred embodiment of the present invention, in step S5, when a situation of illegal entry into the warning area is detected, the crane issues an alarm to remind relevant personnel within the warning area and pop up a warning window on the monitoring screen in the cab of the overhead crane to remind the driver. At the same time, the warning system is linked with the electrical control system, and corresponding measures are taken according to the set discrimination conditions. When necessary, the crane is controlled to stop operating to avoid safety accidents.

[0030] As a preferred embodiment of the present invention, if it is detected that a person approaches the heavy object quickly, the system will immediately stop the operation of the crane. If it is detected that an object is stationary at the edge of the warning area, the system will first issue an alarm and continuously monitor the dynamics of the object.

[0031] The beneficial effects of the present invention are as follows:

[0032] The multi-line lidar of the present invention scans the size of the lifted heavy object in real time and with high precision. The matrix projection lamp projects a warning area accurately below the heavy object according to the size of the heavy object obtained by scanning and the established safe distance for lifting operations. With the help of the camera, the states of personnel and objects within the warning area are monitored in real time. Once it is detected that a person or an object illegally enters the warning area, the warning system for the overhead crane lifting operation issues an alarm and, when necessary, executes a shutdown control instruction for the overhead crane to avoid safety accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 is a schematic structural diagram of the present invention;

[0034] Figure 2 is a partial structural diagram of the present invention;

[0035] Figure 3 is Figure 2 a partial enlarged view of part A in

[0036] Figure 4 is the front view of a part of the structure of the present invention;

[0037] Figure 5 is the method flow chart of the present invention.

[0038] In the figure: 1 - main beam frame; 2 - traveling trolley; 3 - matrix projection lamp; 4 - multi-line lidar; 5 - heavy object; 6 - warning area; 7 - camera; 301 - projection lamp cloud platform. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0039] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Usually, the components of the embodiments of the present invention described and illustrated in the accompanying drawings here can be arranged and designed in various different configurations.

[0040] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed present invention, but merely represents selected embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other.

[0041] As Figures 1 to 4 shown, the warning system for the hoisting operation area of the bridge crane in this embodiment includes a main beam frame 1. A track is provided on the main beam frame 1, and a traveling trolley 2 is installed on the track. A hook is installed on the lower side of the traveling trolley 2, and the hook is connected to a heavy object 5 through a rope; a multi-line lidar 4 and a camera 7 are respectively installed on the lower side of the main beam frame 1. A projection lamp cloud platform 301 is installed on the lower side of the traveling trolley 2, and a matrix projection lamp 3 is installed at the output end of the projection lamp cloud platform 301. The matrix projection lamp 3 projects a warning area 6 on the ground; a warning system is also included, and the multi-line lidar 4, the camera 7, the projection lamp cloud platform 301, and the matrix projection lamp 3 are all electrically connected to the warning system.

[0042] Deploy multi-line lidars 4 at both ends of the main beam frame 1 of the bridge crane to accurately scan the size of the hoisted heavy object 5 in real time. At an appropriate position of the traveling trolley 2 above the hook of the bridge crane, install the projection lamp cloud platform 301 and the matrix projection lamp 3, and accurately project the warning area 6 below the heavy object 5 according to the size of the heavy object 5 obtained by scanning and the established safe distance for hoisting operations. With the camera 7, monitor the status of personnel and objects in the warning area 6 in real time. Once it is detected that a person or an object illegally enters the warning area 6, the warning system for the hoisting operation of the bridge crane issues an alarm, and when necessary, executes a shutdown control instruction on the bridge crane to avoid safety accidents.

[0043] During the rotation of the projection lamp cloud platform 301, it does not interfere with the crane. The projection lamp cloud platform 301 is installed at a suitable position on the traveling trolley 2 above the hook of the bridge crane. During the rotation of the projection lamp cloud platform 301, it does not interfere with the crane, and at the same time, the key area below the heavy object 5 can be clearly observed. The matrix projection lamp 3 is installed on the projection lamp cloud platform 301, and the projection angle of the matrix projection lamp 3 is accurately adjusted according to the control instruction. Cables are laid to connect the matrix projection lamp 3 and the projection lamp cloud platform 301 to the warning system, so that it can project a specific area that meets the safety warning requirements below the heavy object 5 according to the control instruction.

[0044] The multi-line lidar 4 is installed at both ends of the main beam frame 1. The multi-line lidar 4 is installed at a suitable position with a wide view and stability at both ends of the main beam frame 1 of the bridge crane to ensure that the scanning direction of the multi-line lidar 4 can comprehensively and without dead angle cover the operation area of the hoisted heavy object 5. Cables are laid to connect the scanning data of the multi-line lidar 4 to the warning system to provide basic data support for subsequent operation analysis.

[0045] The shooting range of the camera 7 fully covers the warning area 6. On the bridge crane, select the best position that can clearly shoot the warning area 6 projected below the heavy object 5 to install the camera 7. The shooting range of the camera 7 should fully cover the warning area 6. Cables are laid to connect the camera 7 to the warning system to realize the real-time and stable transmission of image data in the warning area 6 and provide a data source for subsequent image recognition and analysis.

[0046] As Figure 5 shown, the warning method for the hoisting operation area of the bridge crane in this embodiment includes the following steps:

[0047] S1: Heavy object 5 size scanning:

[0048] After the bridge crane is powered on, the multi-line lidar 4 is immediately automatically turned on. The hoisting mechanism starts to operate, and the multi-line lidar 4 performs an all-round scan of the hook or the heavy object 5 to obtain accurate size data of the heavy object 5 and transmits the data to the warning system.

[0049] S2: Spatial position recognition:

[0050] 1) Point cloud data preprocessing, feature extraction:

[0051] The original point cloud data obtained by the multi-line lidar 4 is preprocessed and feature extraction is performed to provide basic data for subsequent accurate coordinate conversion.

[0052] 2) Coordinate conversion:

[0053] Taking a fixed point of the bridge crane (such as a corner of the main girder frame 1) as the origin, a global coordinate system of the bridge crane is established. Taking the installation center of the multi-line lidar 4 as the origin, a lidar coordinate system is established.

[0054] Select several fixed points of the bridge crane as calibration objects, and determine the coordinates (x 1i , y 1i , z 1i ) of the calibration objects in the global coordinate system of the bridge crane through measurement and the crane design drawings (i = 1, 2, …, n, where n is the number of calibration objects).

[0055] The multi-line lidar 4 scans the calibration objects to obtain the coordinates (x 2i , y 2i , z 2i ) of the calibration objects in the lidar coordinate system.

[0056] Construct a mathematical model to realize the conversion of the lidar coordinate system to the global coordinate system of the bridge crane, and obtain the accurate position data of the heavy object 5 in the working space.

[0057] 3) Dynamic tracking:

[0058] According to the position and speed of the heavy object 5 at the previous moment, calculate the position at the current moment, and correct it in combination with the real-time measurement data of the multi-line lidar 4, continuously optimize the predicted value of the position of the heavy object 5, and real-time track the position change of the heavy object 5 during the lifting process.

[0059] S3: Determine the coordinates of the warning area 6:

[0060] The height encoder of the bridge crane measures the height of the heavy object 5 in real time. Based on the regulations of the safe distance for hoisting operations at different heights, combined with the size data of the heavy object 5 and the accurate position of the heavy object 5 in space, the coordinates of the range of the warning area 6 that needs to be projected in the global coordinate system of the bridge crane are calculated in real time.

[0061] S4: Project the warning area 6:

[0062] Taking the installation point of the traveling encoder on the traveling trolley 2 of the bridge crane as the origin, a matrix projection lamp 3 coordinate system is established to determine the accurate coordinates of the matrix projection lamp 3.

[0063] During the operation of the traveling trolley 2, the traveling encoder measures the distance deviation between the origin of the matrix projection lamp 3 coordinate system and the origin of the global coordinate system of the bridge crane in real time. Through calculation, the coordinate transformation of the matrix projection lamp 3 to the global coordinate system of the bridge crane is realized.

[0064] The warning system transmits the calculated coordinates of the warning area 6 to the projection lamp cloud platform 301 and the matrix projection lamp 3; the projection lamp cloud platform 301 and the matrix projection lamp 3 are adjusted to appropriate angles according to the coordinate information, and project corresponding red lights below the heavy object 5 to calibrate the warning area 6.

[0065] S5: Real-time monitoring and warning:

[0066] The camera 7 captures the images in the warning area 6 in real time, and the warning system determines whether there are any personnel or objects in the warning area 6 through image recognition.

[0067] When it is detected that there is a situation of illegally entering the warning area 6, the crane issues an alarm to remind the relevant personnel in the warning area 6, and a warning window pops up on the monitoring screen in the cab of the bridge crane to remind the driver; at the same time, the warning system is linked with the electrical control system, and corresponding measures are taken according to the set discrimination conditions. When necessary, the crane is controlled to stop operating to avoid safety accidents. For example, if it is detected that a person is approaching the heavy object 5 quickly, the system will immediately stop the operation of the crane; if it is detected that an object is stationary at the edge of the warning area 6, the system will first issue an alarm and continuously monitor the dynamics of the object.

[0068] The structure of the present invention is simple, the technology is mature, and the manufacturing and installation are easy. Through real-time monitoring and accurate warning, the present invention can effectively reduce the incidence of safety accidents during the hoisting operation of the bridge crane, and provide safety guarantees for on-site operators and equipment. The hardware installation method of the present invention is flexible and has strong versatility. It can be applied to various types and specifications of bridge cranes and has a wide application prospect.

[0069] The present invention is not limited to the above optional implementation manners. Any person can obtain other various forms of products under the inspiration of the present invention. However, no matter what changes are made in its shape or structure, as long as the technical solutions fall within the scope defined by the claims of the present invention, they are all within the protection scope of the present invention.

Claims

1. Bridge crane hoisting operation area early warning system, characterized by: The invention comprises a main beam frame (1), a track is arranged on the main beam frame (1), a running trolley (2) is installed on the track, a hook is installed on the lower side of the running trolley (2), and the hook is connected to a heavy object (5) through a rope; a multi-line laser radar (4) and a camera (7) are respectively installed on the lower side of the main beam frame (1), a matrix projection lamp (3) is installed on the lower side of the running trolley (2), and the matrix projection lamp (3) projects a warning area (6) on the ground.

2. The bridge crane hoisting operation area warning system according to claim 1 is characterized by: A projection lamp platform (301) is installed on the small side of the running trolley (2), and the matrix projection lamp (3) is installed on the lower side of the running trolley (2) through the projection lamp platform (301).

3. The bridge crane hoisting operation area warning system according to claim 2 is characterized by: It also includes an early warning system, and the multi-line laser radar (4), the camera (7), the projection light pan / tilt (301) and the matrix projection light (3) are all electrically connected to the early warning system.

4. The bridge crane hoisting operation area early warning system according to claim 2 is characterized by: During the rotation of the projection lamp platform (301), no interference occurs with the crane.

5. The bridge crane hoisting operation area early warning system according to claim 1 is characterized by: The multi-line laser radar (4) is installed at both ends of the main beam frame (1).

6. The bridge crane hoisting operation area early warning system according to claim 1 is characterized by: The shooting range of the camera (7) fully covers the warning area (6).

7. A bridge crane hoisting operation area early warning method, using the bridge crane hoisting operation area early warning system according to claim 1, characterized in that: The following steps are involved: S1: Heavy object (5) size scan: After the bridge crane is powered on, the multi-line laser radar (4) is automatically turned on immediately; the lifting mechanism starts to operate, and the multi-line laser radar (4) performs a full-range scan of the hook or the weight (5), obtains accurate size data of the weight (5), and transmits the data to the early warning system; S2: Spatial location recognition: Including point cloud data preprocessing, feature extraction, coordinate conversion, and dynamic tracking; S3: Determine the coordinates of the warning area (6): The height encoder of the bridge crane measures the height of the heavy object (5) in real time, and the early warning system calculates the coordinates of the early warning area (6) to be projected in the global coordinate system of the bridge crane in real time according to the provisions of the safe distance for lifting operations at different heights, combined with the size data of the heavy object (5) and the precise position of the heavy object (5) in space; S4: Projection warning area (6): Taking the installation point of the travel encoder on the bridge crane trolley (2) as the origin, a matrix projection lamp (3) coordinate system is established to determine the precise coordinates of the matrix projection lamp (3); During the operation of the trolley (2), the travel encoder measures the distance deviation between the origin of the matrix projection light (3) coordinate system and the origin of the global coordinate system of the bridge crane in real time, and realizes the conversion of the matrix projection light (3) coordinate system to the global coordinate system of the bridge crane through calculation; The early warning system transmits the calculated coordinates of the early warning area (6) to the projection light platform (301) and the matrix projection light (3); the projection light platform (301) and the matrix projection light (3) are adjusted to a suitable angle according to the coordinate information, and a corresponding red light is projected under the heavy object (5) to mark the early warning area (6); S5: Real-time monitoring and warning: The camera (7) captures the image in the warning area (6) in real time, and the warning system determines whether there are people or objects in the warning area (6) through image recognition.

8. The bridge crane hoisting operation area early warning method according to claim 7 is characterized by: Step S2 is specifically as follows: Point cloud data preprocessing and feature extraction: preprocessing the original point cloud data acquired by the multi-line laser radar (4) and extracting features to provide basic data for subsequent precise coordinate conversion; Coordinate transformation: Take a fixed point of the bridge crane as the origin to establish the global coordinate system of the bridge crane; take the installation center of the multi-line laser radar (4) as the origin to establish the laser radar coordinate system; select several fixed points of the bridge crane as calibration objects, and determine the coordinates (x 1i ,y 1i ,z 1i ); where i = 1, 2, ..., n, and n is the number of calibration objects; the multi-line laser radar (4) scans the calibration object to obtain the coordinates (x 2i ,y 2i ,z 2i ) ; construct a mathematical model to realize the conversion of the laser radar coordinate system to the global coordinate system of the bridge crane, and obtain the accurate position data of the heavy object (5) in the working space; Dynamic tracking: Calculate the current position of the heavy object (5) based on its position and speed at the previous moment, and make corrections based on the real-time measurement data of the multi-line laser radar (4), continuously optimize the predicted value of the position of the heavy object (5), and track the position changes of the heavy object (5) during the lifting process in real time.

9. The bridge crane hoisting operation area early warning method according to claim 7, characterized in that: In step S5, when an illegal entry into the warning area (6) is detected, the crane sounds an alarm to alert relevant personnel in the warning area (6), and a warning window pops up on the monitoring screen in the bridge crane driver's cab to alert the driver; at the same time, the warning system is linked with the electrical control system to take corresponding measures according to the set judgment conditions, and control the crane to stop operating when necessary to avoid safety accidents.

10. The bridge crane hoisting operation area early warning method according to claim 7, characterized in that: If a person is detected approaching a heavy object (5) quickly, the system will immediately stop the crane operation; if an object is detected to be stationary at the edge of the warning area (6), the system will first sound an alarm and continue to monitor the object's dynamics.

Images