Crown block state remote monitoring system and method and related equipment

Abstract

The invention discloses a crown block state remote monitoring system and method and related equipment, and relates to the technical field of crown block management, and the system comprises a crown block programmable logic control module which is used for accessing a crown block control signal and generating crown block state data; the wireless communication network module is connected to the crown block programmable logic control module and is used for transmitting the crown block state data; the data acquisition module is connected to the wireless communication network module and is used for receiving and analyzing the crown block state data; the data storage module is connected to the data acquisition module and is used for converting the analyzed crown block state data into relational data and storing the relational data; and the crown block state remote monitoring module is connected to the data storage module and is used for displaying the analyzed crown block state data and generating crown block operation state information based on the analyzed crown block state data.

Description

Technical Field

[0001] This application relates to the technical field of overhead crane management, and in particular, to an overhead crane status remote monitoring system, method, and related devices. Background Art

[0002] In the field of metallurgical steelmaking, overhead cranes, as the core handling equipment in the liquid metal area, undertake key tasks such as ladle lifting and material transfer. Their operating status directly affects production safety and efficiency. Traditional overhead crane control systems usually rely on local Programmable Logic Controllers (PLCs) to achieve automated operations, but there is a lack of effective data interconnection between overhead cranes, forming information islands, making it difficult for operation and maintenance personnel to grasp the equipment status in real time.

[0003] In the prior art, the status monitoring of overhead cranes mainly relies on manual regular inspections or local viewing through configuration software pre-installed on the vehicle end. When the equipment malfunctions, maintenance personnel need to board the vehicle to troubleshoot and manually adjust the PLC program, which is not only cumbersome but also has a lag in response. In addition, there is a lack of unified data integration and analysis means for overhead crane parameters, making it difficult to achieve predictive maintenance and global optimization, severely restricting the improvement of overhead crane operation efficiency. Therefore, there is an urgent need for an overhead crane status remote monitoring system to solve the above-mentioned technical problems. Summary of the Invention

[0004] A series of simplified concepts are introduced in the Summary of the Invention section, which will be further elaborated in detail in the Detailed Description section. The Summary of the Invention section of this application does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the protection scope of the claimed technical solution.

[0005] In a first aspect, this application provides an overhead crane status remote monitoring system, which includes:

[0006] An overhead crane programmable logic control module, configured to access overhead crane control signals and generate overhead crane status data;

[0007] A wireless communication network module, connected to the overhead crane programmable logic control module, configured to transmit the overhead crane status data;

[0008] A data acquisition module, connected to the wireless communication network module, configured to receive and parse the overhead crane status data;

[0009] A data storage module, connected to the data acquisition module, configured to convert the parsed overhead crane status data into relational data and store it;

[0010] The overhead crane status remote monitoring module is connected to the data storage module, and is used to display the parsed overhead crane status data and generate the overhead crane operation status information based on the parsed overhead crane status data.

[0011] In some embodiments, the data storage module is a relational database, wherein the parsed overhead crane status data includes at least one of the overhead crane limit status data, the overhead crane motor status data, the overhead crane frequency converter IGBT status data, the overhead crane equipment replacement cycle status data, the overhead crane alarm status data, the overhead crane driver operation status data, and the overhead crane ladder diagram status data.

[0012] In some embodiments, the overhead crane status remote monitoring module further includes:

[0013] A user interface of the browser / server architecture, which is used to visually display the parsed overhead crane status data;

[0014] A logic processing unit, which extracts the overhead crane operation logic conditions based on the parsed overhead crane status data, and generates the overhead crane operation status information based on the overhead crane operation logic conditions.

[0015] In some embodiments, the overhead crane status remote monitoring system further includes a ground engineer module, and the ground engineer module includes:

[0016] A ground engineer interaction unit, which is used to modify the overhead crane programmable logic control program in response to an input modification instruction;

[0017] A program verification unit, which is used to verify whether the modified program complies with the preset safety rules, and synchronize the modified program to the overhead crane programmable logic control module after the verification passes.

[0018] In a second aspect, the present application proposes an overhead crane status remote monitoring method, and the method includes:

[0019] Generating the overhead crane status data corresponding to the overhead crane control signal through the overhead crane programmable logic control module;

[0020] Transmitting the overhead crane status data to the data acquisition module through the wireless communication network module;

[0021] Using the data acquisition module to parse the overhead crane status data to generate the parsed overhead crane status data;

[0022] Converting the parsed overhead crane status data into relational data, and storing it in a preset database through the data storage module;

[0023] Based on the overhead crane status remote monitoring module, visually displaying the parsed overhead crane status data in real time;

[0024] Generate the statistical information of the overhead crane operation status based on the parsed overhead crane status data.

[0025] In some embodiments, the parsed overhead crane status data includes at least one of the overhead crane limit status data, the overhead crane motor status data, the overhead crane frequency converter IGBT status data, the overhead crane equipment replacement cycle status data, the overhead crane alarm status data, the overhead crane driver operation status data, and the overhead crane ladder diagram status data.

[0026] In some embodiments, the parsed overhead crane status data includes the overhead crane limit status data, the overhead crane motor status data, and the overhead crane driver operation status data. Generating the statistical information of the overhead crane operation status based on the parsed overhead crane status data includes:

[0027] Based on the overhead crane limit status data, count the number of times and the position distribution of the extreme limit triggers of the overhead crane within a preset period, and generate a limit analysis report based on the number of times of extreme limit triggers and the position distribution.

[0028] Extract the current data, speed data, and torque data from the overhead crane motor status data. Based on the current data, speed data, torque data, and a preset motor health model, determine the motor operation stability, and generate a motor performance prompt based on the motor operation stability.

[0029] According to the overhead crane driver operation status data and the preset types of illegal operations, identify the number of illegal operations and the type of each illegal operation, and generate a driver operation compliance evaluation chart based on the number of illegal operations and the type of each illegal operation.

[0030] In some embodiments, it further includes:

[0031] Collect the U-phase temperature parameter, V-phase temperature parameter, and W-phase temperature parameter in the overhead crane frequency converter IGBT status data.

[0032] Compare the U-phase temperature parameter, V-phase temperature parameter, and W-phase temperature parameter with the preset temperature thresholds of the corresponding phases respectively. When any phase temperature parameter is greater than the preset temperature threshold of the corresponding phase, generate a high-temperature alarm signal for the corresponding phase.

[0033] Count the cumulative number of times of triggering of the high-temperature alarm signals of the U-phase, V-phase, and W-phase within a preset time respectively.

[0034] Based on the cumulative number of times of triggering of each phase, the overhead crane equipment replacement cycle status data, and a preset life prediction model, calculate the remaining service life of the frequency converter.

[0035] Generate a frequency converter maintenance prompt message according to the remaining service life and a preset maintenance strategy.

[0036] In some embodiments, it further includes:

[0037] Receive modification instructions through the ground engineer module, modify the programmable logic control program of the overhead crane, and verify whether the modified program complies with the preset safety rules.

[0038] In a third aspect, an electronic device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program stored in the memory, it implements the steps of the cable tunnel escape guidance method according to any one of the above second aspects.

[0039] In summary, through the cooperation of the overhead crane programmable logic control module, the wireless communication network module, and the data acquisition module, this application realizes the efficient acquisition and real-time transmission of the overhead crane status data; combined with the relational data conversion and storage capabilities of the data storage module, as well as the multi-dimensional data display and statistical functions of the overhead crane status remote monitoring module, it effectively breaks the overhead crane data island and improves the integration and operability of the monitoring data. This system can generate the overhead crane operation status information in real time, provide accurate fault location and maintenance decision support for the operation and maintenance personnel, and improve the safety and management efficiency of the overhead crane operation. Description of the Drawings

[0040] By reading the following detailed description of the preferred embodiments, various other advantages and benefits will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered to be a limitation of this specification. Moreover, throughout the drawings, the same reference numerals are used to represent the same components. In the drawings:

[0041] Figure 1 It is a schematic structural diagram of an overhead crane status remote monitoring system provided by an embodiment of this application;

[0042] Figure 2 It is another schematic structural diagram of an overhead crane status remote monitoring system provided by an embodiment of this application;

[0043] Figure 3 It is a schematic flowchart of an overhead crane status remote monitoring method provided by an embodiment of this application;

[0044] Figure 4 It is a schematic diagram of the overhead crane limit status interface monitoring provided by an embodiment of this application;

[0045] Figure 5 It is a schematic diagram of the overhead crane frequency converter IGBT temperature interface monitoring provided by an embodiment of this application;

[0046] Figure 6 It is a schematic diagram of the overhead crane alarm interface monitoring provided by an embodiment of this application;

[0047] Figure 7Schematic diagram of the overhead crane driver operation interface monitoring provided by the embodiment of the present application;

[0048] Figure 8 Schematic diagram of the overhead crane PLC operating condition interface monitoring provided by the embodiment of the present application;

[0049] Figure 9 Schematic diagram of an electronic device for remote monitoring of the overhead crane state provided by the embodiment of the present application.

[0050] Among them, the corresponding relationship between the reference numerals in the figure and the component names is as follows:

[0051] 10 is the overhead crane state remote monitoring system, 110 is the overhead crane programmable logic control module, 120 is the wireless communication network module, 130 is the data acquisition module, 140 is the data storage module, 150 is the overhead crane state remote monitoring module, and 160 is the ground engineer module. Detailed implementation manners

[0052] The terms "first", "second", "third", "fourth", etc. (if any) in the specification, claims and above-mentioned drawings of the present application are used to distinguish similar objects, and do not necessarily need to be used to describe a specific order or sequence. It should be understood that such used data can be interchanged under appropriate circumstances so that the embodiments described herein can be implemented in an order different from that illustrated or described herein. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device comprising a series of steps or units does not necessarily have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices. The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all of the embodiments.

[0053] Please refer to Figure 1 , Figure 1 which is a schematic diagram of the structure of an overhead crane state remote monitoring system 10, and specifically may include:

[0054] The overhead crane programmable logic control module 110 is used to access the overhead crane control signal and generate overhead crane status data; the wireless communication network module 120 is connected to the overhead crane programmable logic control module 110 and is used to transmit the overhead crane status data; the data acquisition module 130 is connected to the wireless communication network module 120 and is used to receive and analyze the overhead crane status data; the data storage module 140 is connected to the data acquisition module 130 and is used to convert the analyzed overhead crane status data into relational data and store it; the overhead crane status remote monitoring module 150 is connected to the data storage module 140 and is used to display the analyzed overhead crane status data and generate the overhead crane operation status information based on the analyzed overhead crane status data.

[0055] Exemplarily, the overhead crane status remote monitoring system 10 includes an overhead crane programmable logic control module 110, a wireless communication network module 120, a data acquisition module 130, a data storage module 140, and an overhead crane status remote monitoring module 150. Among them, the overhead crane programmable logic control module 110 is used to access the overhead crane control signal and generate overhead crane status data, and transmits the overhead crane status data to the data acquisition module 130 through the wireless communication network module 120. The data acquisition module 130 analyzes the received overhead crane status data and transmits the analyzed data to the data storage module 140, and the data storage module 140 converts it into relational data and stores it.

[0056] The overhead crane status remote monitoring module 150 is connected to the data storage module 140, and is responsible for real-time displaying the analyzed overhead crane status data and generating the overhead crane operation status information based on preset logic conditions. Through the user interaction interface of the browser / server architecture, the operation and maintenance personnel can intuitively view multi-dimensional data such as the overhead crane limit status, motor status, and inverter IGBT status, and dynamically analyze the operation logic conditions in combination with the logic processing unit.

[0057] The wireless communication network module 120 adopts a gigabit wireless AP or 5G network technology to ensure the stable transmission of high-frequency overhead crane status data. The data storage module 140 relies on a relational database (such as MySQL) to integrate the overhead crane equipment replacement cycle status data, alarm records, and driver operation records to form a structured data pool, providing a unified data source for the overhead crane status remote monitoring module 150.

[0058] Through the collaborative operation of the above modules, the overhead crane status remote monitoring system 10 realizes the remote real-time monitoring and intelligent analysis of the overhead crane operation status. The system 10 can dynamically generate equipment health assessment, abnormal alarm prompts, and maintenance decision support, effectively improving the efficiency and safety of overhead crane management and solving the problems of data islands and response lags in traditional monitoring systems.

[0059] In summary, the overhead crane status remote monitoring system 10 of the embodiments of the present application collects overhead crane control signals in real time through the overhead crane programmable logic control module 110 and generates overhead crane status data. The wireless communication network module 120 uses a gigabit wireless AP or 5G technology to achieve efficient and stable data transmission. After the data acquisition module 130 analyzes the received raw data, the data storage module 140 converts it into relational data and stores it in a database such as MySQL, forming a multi-dimensional structured data pool. The overhead crane status remote monitoring module 150 displays the analyzed overhead crane status data in real time through the user interface of the browser / server architecture, and dynamically generates equipment health assessment, abnormal alarm labels, and maintenance decision support information based on preset logical conditions. At the same time, combined with the remote program modification and security verification functions of the ground engineer module 160, it realizes the global visual management and intelligent analysis of the overhead crane operation status, effectively breaks data islands, improves the fault response speed, enhances the operation safety and maintenance efficiency of the overhead crane, and solves the technical problems of insufficient real-time performance, lagging maintenance, and scattered operations in traditional monitoring systems.

[0060] In some examples, the data storage module 140 is a relational database. Among them, the analyzed overhead crane status data includes at least one of overhead crane limit status data, overhead crane motor status data, overhead crane frequency converter IGBT status data, overhead crane equipment replacement cycle status data, overhead crane alarm status data, overhead crane driver operation status data, and overhead crane ladder diagram status data.

[0061] Exemplarily, as the core data hub of the overhead crane status remote monitoring system 10, the data storage module 140 uses a relational database to structurally store the analyzed overhead crane status data. The analyzed overhead crane status data includes at least one of overhead crane limit status data, overhead crane motor status data, overhead crane frequency converter IGBT status data, overhead crane equipment replacement cycle status data, overhead crane alarm status data, overhead crane driver operation status data, and overhead crane ladder diagram status data. Among them, the overhead crane limit status data collects the front and rear extreme limit trigger statuses of mechanisms such as the overhead crane's main trolley, auxiliary trolley, etc., and the end beam door switch status in real time through the overhead crane programmable logic control module 110; the overhead crane motor status data includes the current, speed, and torque parameters of the main hoist and auxiliary hoist motors; the overhead crane frequency converter IGBT status data records the temperatures of the U phase, V phase, and W phases and the circuit board temperature; the overhead crane equipment replacement cycle status data integrates maintenance information such as equipment number, installation date, and replacement cycle; the overhead crane alarm status data covers abnormal events such as limit parking and inverter failure; the overhead crane driver operation status data counts the types and frequencies of illegal operations; the overhead crane ladder diagram status data feeds back the satisfaction status of the interlock conditions in real time by simulating the PLC program logic conditions.

[0062] After receiving the original high-frequency signal transmitted by the wireless communication network module 120, the data acquisition module 130 parses it into the above-mentioned structured data according to a preset protocol. For example, after parsing the binary signal generated by the overhead crane programmable logic control module 110, the limit trigger signal is converted into a status label of "front extreme limit triggered", the motor current value is mapped to an alarm event of "main hoist current exceeding the limit", and the IGBT temperature parameters are classified and stored independently for phases U, V, and W. The data storage module 140 stores the parsed data according to the relational database table structure, supports multi-dimensional queries based on time, overhead crane number, equipment type, etc., and provides an efficient data access interface for the overhead crane status remote monitoring module 150.

[0063] Based on the structured data in the data storage module 140, the overhead crane status remote monitoring module 150 dynamically displays the equipment status through the user interface of the browser / server architecture. For example, the overhead crane limit status data shows the triggering situation of the extreme limit in real time with color identification, the overhead crane frequency converter IGBT status data generates a temperature trend curve, and the overhead crane driver operation status data is associated with the type of illegal operation to generate a compliance report. The relational data design of the data storage module 140 effectively supports the full life cycle management of the overhead crane operation status and the decision-making of predictive maintenance.

[0064] In some instances, the overhead crane status remote monitoring module 150 further includes:

[0065] A user interface of the browser / server architecture, which is used to visually display the parsed overhead crane status data;

[0066] A logic processing unit, which extracts the overhead crane operation logic conditions based on the parsed overhead crane status data; and generates the overhead crane operation status information based on the overhead crane operation logic conditions.

[0067] Exemplarily, the overhead crane status remote monitoring module 150 includes a user interface of the browser / server architecture and a logic processing unit. The user interface is built based on the BS architecture and visually displays the parsed overhead crane status data in real time through a web page form, including at least one of the overhead crane limit status data, the overhead crane motor status data, the overhead crane frequency converter IGBT status data, the overhead crane equipment replacement cycle status data, and the overhead crane alarm status data. The user interface supports dynamic rendering of multi-dimensional data. For example, it marks the overhead crane limit trigger status with color, shows the motor current fluctuation trend with a curve graph, simulates the PLC program logic condition status with a ladder diagram, and provides maintenance reminders for the overhead crane equipment replacement cycle and compliance evaluation charts for the driver's operations, enabling the operation and maintenance personnel to remotely and intuitively grasp the overall picture of the overhead crane operation and quickly locate anomalies.

[0068] Based on the parsed overhead crane status data, the logic processing unit extracts the operating logic conditions of the overhead crane, including the interlock safety conditions in the PLC program, the equipment start-stop logic, and the operation compliance rules. The logic processing unit dynamically verifies the operating logic conditions through preset analysis models (such as the motor health model and the life prediction model). When it detects that the logic conditions are not met, it generates the overhead crane operating status information including the decrease in equipment health, the alarm of interlock failure, and the prompt of illegal operation. For example, if the overhead crane limit status data shows that the end beam door is not closed and the main hoist motor current exceeds the limit, the logic processing unit will generate the alarm of "safety interlock failure" and the prompt of "motor overload" through correlation analysis and synchronize them to the user interaction interface for highlighting.

[0069] The user interaction interface works in coordination with the logic processing unit to achieve a closed-loop of data display and intelligent analysis. After receiving the operating status information generated by the logic processing unit, the user interaction interface guides the operation and maintenance personnel to perform targeted operations through the dynamically updated alarm list, the health dashboard, and the maintenance task list.

[0070] Please refer to Figure 2 , which is another structural schematic diagram of the overhead crane status remote monitoring system 10 provided by the embodiment of the present application. The overhead crane status remote monitoring system 10 further includes a ground engineer module 160, and the ground engineer module 160 includes:

[0071] The ground engineer interaction unit is used to modify the overhead crane programmable logic control program in response to the input modification instruction;

[0072] The program verification unit is used to verify whether the modified program complies with the preset safety rules and synchronize the modified program to the overhead crane programmable logic control module after the verification passes.

[0073] Exemplarily, the ground engineer module 160 is composed of the ground engineer interaction unit and the program verification unit. The ground engineer interaction unit receives the input modification instruction through the user interaction interface of the browser / server architecture, provides a visual program editing interface for the operation and maintenance personnel to adjust the overhead crane programmable logic control program online, such as modifying the PLC interlock conditions, adjusting the motor operation parameters, or updating the equipment maintenance strategy. The ground engineer interaction unit converts the modification instruction into a program modification request and transmits it to the program verification unit for security verification, ensuring that the modification operation can be completed without boarding the vehicle, which significantly improves the convenience of remote operation and maintenance.

[0074] The program verification unit performs multi-dimensional verification on the modified program based on the preset safety rules, including syntax normativeness check, logic conflict detection (such as conflict with the safety threshold in the crane limit status data and motor status data) and matching with industry safety standards. For example, if the modified program deletes the end beam door closing interlock condition, the program verification unit will compare the mandatory safety clauses in the preset safety rules, determine that the modification is illegal and intercept the synchronization operation; if the modified content passes the verification, the program verification unit will synchronize the modified program logic to the crane programmable logic control module 110 in real time to ensure the online update and safe operation of the crane control logic.

[0075] The ground engineer module 160 realizes remote safety modification and real-time effectiveness of the overhead crane control program through the collaboration of the ground engineer interaction unit and the program verification unit. The modified program running status is dynamically fed back through the user interaction interface of the overhead crane status remote monitoring module 150, for example, marking the updated interlocking conditions in the ladder diagram logic condition status display, and verifying the modification effect in combination with the overhead crane alarm status data. This design solves the drawback of on-site debugging in traditional operation and maintenance, reduces the risk of human operation, and ensures the reliability and compliance of the overhead crane control logic through automated safety verification.

[0076] It should be noted that in the embodiment of the present application, the crane driving control PLC preferably adopts Siemens 300PLC or Siemens 1500PLC series, and the PLC establishes a communication connection with the gigabit wireless AP network by adding a dedicated communication module (such as Siemens PN module) to realize the transmission of the crane control signal to the crane programmable logic control module 110. Since the driving control belongs to the internal network of the PLC and is physically isolated from the wireless communication network module 120 of the remote monitoring system 10, the security of the crane PLC data download process is ensured by configuring an independent IP address and security protocol, and external network interference with the core control logic is avoided.

[0077] The wireless communication network module 120 uses gigabit wireless AP or operator 5G wireless network technology to build a high-speed data transmission channel between the overhead crane programmable logic control module 110 and the ground data acquisition module 130. Gigabit wireless AP is suitable for fixed coverage scenarios in factory areas, providing low-latency, high-bandwidth localized communication; 5G network supports wide-area coverage and real-time data return of mobile overhead cranes. Both can be flexibly selected according to actual deployment requirements to ensure stable transmission of overhead crane status data (such as high-frequency motor current and limit trigger signals) and seamless access to the ground system.

[0078] See also Figure 3 , is a flow chart of a method for remotely monitoring the state of an overhead crane provided in an embodiment of the present application, comprising:

[0079] S210. Generate the overhead crane status data corresponding to the overhead crane control signal through the overhead crane programmable logic control module;

[0080] Exemplarily, the overhead crane programmable logic control module receives the overhead crane control signal in real time, including the trolley movement instruction, the main hoist motor start / stop command, the limit switch trigger signal, and the frequency converter control parameters, etc. The control signal is parsed and processed through the built-in logic program to generate the corresponding overhead crane status data. The status data covers the core parameters of the overhead crane operation, such as the trolley and crab coordinate positions, the main and auxiliary hoist heights, the load weight, the motor current and torque values, the frequency converter IGBT temperature, and the end beam door switch status, and is converted into a structured format through a preset data encapsulation protocol, providing a standardized data input for subsequent transmission and analysis.

[0081] Specifically, the overhead crane programmable logic control module realizes the real-time generation of status data based on the dynamic matching of the control signal and the sensor feedback signal. For example, when receiving the trolley movement instruction, the module synchronously collects the real-time speed, current, and position encoder signals of the trolley drive motor, combines the limit switch status to judge whether the trolley is in the safe operation range, and comprehensively generates the overhead crane status data including the position coordinates, movement speed, and safety status label. Such data is integrated through the internal data bus of the module to ensure high-frequency collection and low-latency output, providing an accurate and real-time data source for the overhead crane status remote monitoring system.

[0082] S220. Transmit the overhead crane status data to the data acquisition module through the wireless communication network module;

[0083] Exemplarily, the overhead crane status data is transmitted through the wireless communication network module. The wireless communication network module constructs a high-speed communication link based on the gigabit wireless AP or 5G wireless network technology. The structured status data generated by the overhead crane programmable logic control module (including the overhead crane position, motor parameters, limit status, and frequency converter temperature, etc.) is encapsulated through a preset transmission protocol (such as Modbus TCP or OPC UA) and sent to the ground data acquisition module via the wireless channel. During the data transmission process, a redundant check and data encryption mechanism are adopted to ensure the integrity and security of the high-frequency signal. At the same time, the network resources are optimized through the dynamic bandwidth allocation technology to meet the real-time transmission requirements of the overhead crane status data.

[0084] Specifically, the wireless communication network module adaptively selects the communication mode according to the deployment scenario: in a fixed factory area environment, a gigabit wireless AP provides low-latency and high-stability local transmission, supporting concurrent access of multiple overhead cranes; for mobile overhead cranes or wide-area coverage scenarios, the 5G network ensures data transmission priority through slicing technology, enabling cross-regional seamless roaming and real-time backhaul. After receiving the data, the data acquisition module unpacks, converts the format, and filters anomalies of the data through a multi-threaded parsing engine, generates a standardized parsing result, and pushes it to the data storage module, providing low-latency and highly reliable data input for subsequent monitoring and analysis. The above design effectively solves the wiring limitations and signal attenuation problems of traditional wired transmission, improving the flexibility and scalability of the overhead crane status monitoring system.

[0085] S230. Use the data acquisition module to parse the overhead crane status data to generate the parsed overhead crane status data.

[0086] Exemplarily, the data acquisition module processes the received overhead crane status data in real time through a multi-threaded parsing engine. The module first unpacks and parses the format of the original data, converts the data stream encapsulated based on the Modbus TCP or OPC UA protocol into a standardized structure (such as JSON or time series data format), and performs data integrity verification to eliminate abnormal or redundant signals; subsequently, through a preset rule engine, the parsed data is subjected to logical association and tagging processing. For example, the motor current, speed, and torque data are associated with specific equipment numbers, the limit trigger signal is mapped to the overhead crane coordinate position, and the frequency converter temperature data is classified into the corresponding phase, forming a multi-dimensional structured data set, providing highly available input for subsequent storage and analysis.

[0087] The parsed overhead crane status data includes overhead crane limit status data (including extreme limit trigger positions and end beam door status), motor status data (including current, speed, torque, and health status tags), frequency converter IGBT status data (including U / V / W phase temperatures and alarm indicators), equipment replacement cycle status data (including installation date and remaining life), and driver operation records (including operation type and timestamp). The data acquisition module caches high-frequency data through a time series database and writes it in batches to a relational database, ensuring that the data storage module can efficiently support the real-time query, historical backtracking, and statistical analysis requirements of the overhead crane status remote monitoring module, ultimately realizing the full-life cycle monitoring and intelligent decision-making of the overhead crane operation status.

[0088] S240. Convert the parsed overhead crane status data into relational data and store it in a preset database through the data storage module.

[0089] Exemplarily, the data storage module converts and stores the parsed overhead crane status data according to a preset relational database table structure. The parsed data includes overhead crane limit status data, motor operation parameters, inverter IGBT temperature, alarm event records, etc., which are converted into standardized fields of the database table through field mapping rules. For example, the trolley coordinates, end beam door switch status, and trigger timestamp in the overhead crane limit status data are respectively mapped to the "position coordinates", "door status", and "recording time" fields in the database; the current, speed, and torque parameters in the motor status data are associated and stored according to the equipment number and timestamp to form a time-series data table. During the data conversion process, a data type verification and null value filling mechanism is adopted to ensure data integrity and consistency. For example, non-numerical alarm event descriptions are converted into enumeration types, and missing temperature sampling values are marked as "invalid data" and a re-sampling instruction is triggered.

[0090] The converted relational data is written into a preset database (such as MySQL) through the data storage module, supporting efficient querying and statistical analysis. The database table design adopts a primary key-foreign key association and index optimization strategy. For example, the overhead crane number and timestamp are used as a composite primary key to accelerate data retrieval by equipment and time range; the alarm record table is associated with the equipment information table through a foreign key to achieve cross-table joint query. The stored data provides a structured data source for the overhead crane status remote monitoring module. For example, functions such as time-series analysis of limit trigger times, trend prediction of motor current, and threshold alarm of inverter temperature are all implemented based on the relational data in the database. The data storage module uses transaction management and batch writing technologies to ensure storage efficiency and reliability in high-frequency data scenarios, supporting the full life cycle management of the overhead crane operation status.

[0091] S250. Based on the overhead crane status remote monitoring module, the parsed overhead crane status data is displayed in real time;

[0092] Exemplarily, the overhead crane status remote monitoring module displays the parsed overhead crane status data in real time through a browser / server architecture user interface to achieve visual monitoring of the operation status. The user interface presents key information such as overhead crane limit status, motor operation parameters, and inverter IGBT temperature in the form of dynamic charts, color identifications, and data tables. For example, the overhead crane limit status data is displayed in a real-time updated coordinate chart to show the extreme limit trigger positions of the trolley and crab, and the normal and over-limit statuses are distinguished by red and green colors; the motor current, speed, and torque parameters are shown in a line chart to display historical trends and real-time fluctuations; the inverter temperature data dynamically reflects the temperature changes of each phase through a heat map or line chart. When over-temperature is detected, the interface automatically pops up an alarm window and highlights the abnormal phase.

[0093] The logic processing unit of the module generates statistical information and decision support content based on the parsed data. For example, it generates a device stability report by analyzing the triggering frequency of the overhead crane limit, or evaluates the device life by combining the motor parameters with a preset health model. Users can switch the monitored overhead crane, adjust the display parameters, or view the historical records through interface interaction. During the data display process, the WebSocket protocol is used to achieve real-time communication between the front and back ends, ensuring low-latency updates of high-frequency data. At the same time, the interface supports multi-terminal access, and operation and maintenance personnel can monitor the status of the overhead crane in real time through a PC, tablet, or mobile phone, improving the monitoring flexibility and response efficiency. Through intuitive visualization and intelligent analysis, this module provides accurate decision-making basis for the operation management of the overhead crane.

[0094] S260. Generate the statistical information of the overhead crane operation status based on the parsed overhead crane status data.

[0095] Exemplarily, based on the parsed overhead crane status data, the overhead crane status remote monitoring module generates multi-dimensional operation status statistical information through preset analysis models and algorithms. The statistical information includes content such as device health assessment, operation compliance analysis, and maintenance decision support. Specifically, the logic processing unit extracts the number of extreme limit trigger times and position distribution in the overhead crane limit status data, and generates a limit stability report in combination with the time dimension. The current, speed, and torque parameters in the overhead crane motor status data are calculated for the operation stability score through a preset motor health model (such as vibration analysis, load balancing algorithm), and the motor performance tips are output. The overhead crane driver operation status data is matched with a preset illegal operation type library, and the frequency and type of illegal operations are counted to generate a driver operation compliance assessment chart. The analysis process uses time series data analysis, clustering algorithms, and threshold comparison technologies to ensure the accuracy and operability of the statistical results.

[0096] The generated statistical information is further associated with the device replacement cycle status data and a preset life prediction model to achieve predictive maintenance decisions. For example, based on the cumulative over-temperature times and historical replacement records of the IGBT temperature data of the frequency converter, the remaining service life is calculated and maintenance priority suggestions are generated. Combining the fault types and frequencies in the overhead crane alarm status data, the maintenance plan is optimized and maintenance resources are allocated. The statistical information is dynamically displayed through the user interaction interface of the browser / server architecture. For example, the device health index is summarized in the form of a dashboard, or the high-fault areas are presented through a heat map. The statistical information provides data-driven decision-making basis for operation and maintenance personnel, such as adjusting the overhead crane operation parameters, preferentially replacing high-loss components, or strengthening driver operation training, so as to improve the operation efficiency of the overhead crane, reduce the risk of sudden failures, and extend the device life cycle.

[0097] In some instances, the parsed overhead crane status data includes at least one of the overhead crane limit status data, the overhead crane motor status data, the overhead crane frequency converter IGBT status data, the overhead crane equipment replacement cycle status data, the overhead crane alarm status data, the overhead crane driver operation status data, and the overhead crane ladder diagram status data.

[0098] Exemplarily, the parsed overhead crane status data includes core categories such as the overhead crane limit status data, the overhead crane motor status data, and the overhead crane frequency converter IGBT status data. The overhead crane limit status data forms a structured record by collecting the limit trigger signals of the overhead crane's main trolley, auxiliary trolley, and end beam door switch status in real time, such as tags like "front limit of the main trolley has been triggered" and "end beam door is not closed"; the overhead crane motor status data includes the current, speed, and torque parameters of the main hoist and auxiliary hoist motors, which are converted into digital signals through an analog input module and associated with time stamps to evaluate the motor load balance and operation stability; the overhead crane frequency converter IGBT status data records the temperatures of the U phase, V phase, and W phases and the circuit board temperature, triggers over-temperature alarms through threshold comparison, and predicts the equipment life based on the historical temperature trend. After being parsed by the data acquisition module, the above data is stored as standardized fields in a relational database to support real-time monitoring and statistical analysis.

[0099] Furthermore, the parsed data also includes the overhead crane equipment replacement cycle status data, the overhead crane alarm status data, the overhead crane driver operation status data, and the overhead crane ladder diagram status data. The overhead crane equipment replacement cycle status data integrates information such as equipment number, installation date, and maintenance cycle, and generates replacement reminders by combining the operation duration and failure frequency; the overhead crane alarm status data records abnormal events such as limit parking and inverter failures, and stores them classified by alarm type, time, and location for fault cause analysis; the overhead crane driver operation status data counts the types and occurrence frequencies of illegal operations and generates an operation compliance evaluation report; the overhead crane ladder diagram status data simulates the PLC program logic conditions and real-time feedbacks the status of the interlock conditions being met, and triggers fault marking when the logic link is interrupted. The integration and correlation analysis of multi-dimensional data provide a comprehensive data basis for the intelligent monitoring and predictive maintenance of the overhead crane operation status.

[0100] In some instances, the parsed overhead crane status data includes the overhead crane limit status data, the overhead crane motor status data, and the overhead crane driver operation status data. Based on the parsed overhead crane status data, overhead crane operation status statistical information is generated, including:

[0101] Based on the overhead crane limit status data, the number of times the overhead crane's limit is triggered and the position distribution within a preset period are statistically analyzed, and a limit analysis report is generated based on the number of times the limit is triggered and the position distribution.

[0102] Extract the current data, speed data, and torque data from the overhead crane motor status data. Based on the current data, speed data, torque data, and a preset motor health model, determine the motor operation stability, and generate a motor performance prompt based on the motor operation stability;

[0103] According to the overhead crane driver operation status data and preset illegal operation types, identify the number of illegal operations and the type of each illegal operation, and generate a driver operation compliance evaluation chart based on the number of illegal operations and the type of each illegal operation.

[0104] Exemplarily, based on the overhead crane limit status data, the system collects trigger signals in real time through high-precision sensors installed at the limit positions, and records the number of times the overhead crane reaches the limit position and the trigger position coordinates within a preset period. The system statistically analyzes the number of triggers through a data aggregation algorithm, and generates a heat map or distribution density map in combination with the position distribution, intuitively reflecting the limit areas that the overhead crane frequently touches during operation. For example, if the number of triggers in a certain area is significantly higher than other areas, the limit analysis report will mark this position as a high-risk area and recommend checking the mechanical limit device or adjusting the overhead crane operation parameters to reduce equipment wear and safety hazards.

[0105] The system extracts the real-time current, speed, and torque parameters from the overhead crane motor status data, and conducts multi-dimensional analysis through a preset motor health model (such as a degradation prediction model based on neural network or physical modeling). The current data is used to detect overload or underload abnormalities, the speed data is used to evaluate the running smoothness, and the torque data reflects the load fluctuation situation. For example, if the current fluctuation exceeds the model threshold, the system determines that the motor has an overheating risk and generates a "motor overload warning" prompt; if the phase difference between the speed and torque continues to increase, it prompts "the drive system is abnormal and needs maintenance". Through comprehensive index analysis, a motor performance score and maintenance suggestions are generated, providing data support for preventive maintenance.

[0106] The overhead crane driver operation status data is collected in real time through the joystick sensor, camera, and operation log. The system performs pattern matching according to the preset illegal operation types (such as excessive emergency stop frequency, speeding, and operating in a non-safe area). Illegal operation events are identified through time series analysis, and the time stamp, operation type, and duration of each illegal operation are recorded. For example, if it is detected that the driver triggers an emergency stop 3 times within 10 minutes, the system marks it as "frequent emergency stop violation"; if the overhead crane speeds in the restricted area, it is recorded as "area speeding violation". After data aggregation, a driver operation compliance evaluation chart is generated, including a pie chart of the distribution of illegal operation types, a line chart of the time trend, and a radar chart of the comprehensive compliance rate, providing a quantitative basis for operation training and management.

[0107] In some instances, it further includes:

[0108] Collect the U-phase temperature parameter, V-phase temperature parameter, and W-phase temperature parameter in the IGBT status data of the overhead crane frequency converter;

[0109] Compare the U-phase temperature parameter, V-phase temperature parameter, and W-phase temperature parameter with the preset temperature thresholds of the corresponding phases respectively. When any phase temperature parameter is greater than the preset temperature threshold of the corresponding phase, generate a high-temperature alarm signal for the corresponding phase;

[0110] Count the cumulative trigger times of the high-temperature alarm signals of the U-phase, V-phase, and W-phase within the preset time respectively;

[0111] Calculate the remaining service life of the frequency converter based on the cumulative trigger times of each phase, the status data of the overhead crane equipment replacement cycle, and the preset life prediction model;

[0112] Generate a maintenance prompt message for the frequency converter according to the remaining service life and the preset maintenance strategy.

[0113] Exemplarily, the U-phase, V-phase, and W-phase temperature parameters of the IGBT module are collected in real time through the temperature sensors integrated in the overhead crane frequency converter. The sampling frequency is dynamically adjusted according to the working load of the frequency converter to ensure data accuracy and real-time performance. The temperature parameter of each phase is compared with the preset threshold (set based on the temperature resistance limit of the IGBT material and historical operation data) in real time. For example, the U-phase threshold is set to 85 °C. If it is detected that the U-phase temperature reaches 90 °C, a "U-phase high-temperature alarm signal" is generated and pushed to the monitoring terminal through the control device to trigger the sound and light alarm and log record.

[0114] The system counts the cumulative trigger times of the high-temperature alarm signals of the U-phase, V-phase, and W-phase within the preset time window respectively, combines the status data of the overhead crane equipment replacement cycle (such as the designed life of the IGBT module and the running duration) and the preset life prediction model (such as the Arrhenius equation-based or machine learning degradation model) to calculate the remaining service life of the frequency converter. For example, if the U-phase accumulatively triggers 50 high-temperature alarms within 30 days, quantify the impact of the temperature exceeding the standard on the aging of the IGBT insulation layer, output the remaining life as 70% of the original designed life, and label it as "high risk level".

[0115] Based on the remaining service life calculation results and preset maintenance strategies (such as priority classification, spare parts inventory status), generate maintenance prompt information for the frequency converter. For example, when the remaining life is less than 1 month, prompt "Immediately replace the U-phase IGBT component, priority: urgent"; when the remaining life is 2 - 3 months, suggest "Planned maintenance, recommended spare parts procurement". The prompt information is associated with the equipment number, location, and maintenance history, and is pushed to the operation and maintenance terminal through the user interaction interface, and is synchronously updated to the maintenance work order system. Further analyze the maintenance requirements of multiple overhead cranes, optimize resource allocation, reduce downtime, and extend the overall equipment life cycle.

[0116] In some examples, it further includes:

[0117] Receive modification instructions through the ground engineer module, modify the programmable logic control program of the overhead crane, and verify whether the modified program complies with the preset safety rules.

[0118] Exemplarily, the ground engineer module receives modification instructions input by an authorized user through the user interaction interface of the browser / server architecture, such as adjusting the overhead crane motor parameters, updating the PLC ladder diagram logic conditions, or modifying the equipment maintenance cycle. The user selects the target overhead crane and the program logic to be modified through the interface, and the ground engineer interaction unit converts the operation instructions into executable code and generates a program modification request. For example, when modifying the current threshold of the main hoist motor, the user inputs a new value, and the interaction unit generates a structured request including the equipment number, parameter type, and new threshold, and transmits it to the program verification unit through an encrypted channel.

[0119] The program verification unit performs multi-dimensional security verification on the modified program, including logical condition conflict detection (such as whether deleting the "end beam door closed" interlock condition causes a safety hazard), parameter legality check (such as whether the current threshold exceeds the equipment rated range), and operation permission authentication. After the verification passes, the modified program is encrypted and transmitted to the overhead crane programmable logic control module through the wireless communication network module, and the overhead crane ladder diagram status data and equipment parameters in the data storage module are synchronously updated. For example, the updated PLC program logic is refreshed in real time in the user interaction interface. If the modification causes an abnormal limit state, the system automatically triggers an alarm and marks the fault link to ensure the safety of the modification operation and the continuity of system operation.

[0120] Please refer to Figure 4 , which is a schematic diagram of the overhead crane limit state interface monitoring provided by the embodiment of the present application, including:

[0121] The basic information of the overhead crane includes the crane number, the coordinates of the trolley, the coordinates of the crab, the height of the crane, the weight of the ladle carried by the crane, and the time of obtaining the status, etc. The equipment to be monitored includes the overhead crane trolley, the main crab, the auxiliary crab, the main hoist, and the auxiliary hoist mechanisms. The monitoring content involves the front limit, the front pre-limit, the rear limit, and the rear pre-limit status of each mechanism. For the main hoist brake, it is also necessary to monitor its open state, the anti-collision limit, and the pre-limit state, as well as the main hoist overload limit alarm and the end beam door switch alarm, etc. In terms of monitoring display, the limit name is located on the left side of the icon, and the status is displayed on the right side. When the limit is triggered, the white dot is on the right and the background turns green; when the limit is not triggered, the white dot is on the left and the background is red.

[0122] For the monitoring of the overhead crane motor status, the motor equipment involved includes the main hoist, the auxiliary hoist, the main crab, the auxiliary crab, and the trolley equipment. The monitored status parameters include current, speed, and torque, etc. In the display form, the motor monitoring points are located on the left side of the icon, and the black numbers in the white square on the right represent the motor status values, and the unit is marked on the right side of the icon. In this way, a comprehensive and intuitive monitoring of the overhead crane limit status and motor status is achieved, providing a strong guarantee for the safe and stable operation of the overhead crane.

[0123] Please refer to Figure 5 , which is a schematic diagram of the overhead crane frequency converter IGBT temperature interface monitoring provided by the embodiment of the present application, including:

[0124] The temperature data of the frequency converter comes from its internal monitoring parameters and is obtained through the real-time communication between the frequency converter and the overhead crane programmable logic control module. Specifically, the frequency converter equipment monitored by the interface includes key drive units such as main hoist 1, main hoist 2, auxiliary hoist, trolley 1, trolley 2, main crab 1, main crab 2, and auxiliary crab, covering the frequency conversion control core components of each moving mechanism of the overhead crane. For each frequency converter equipment, the interface displays the U-phase temperature, V-phase temperature, W-phase temperature, and internal circuit board temperature parameters of its IGBT module in real time, forming a multi-dimensional temperature monitoring system.

[0125] The interface layout adopts a standardized design. The name of the monitored frequency converter equipment and the specific phase (such as "main hoist 1 - U phase") are marked on the left side of the icon, and the real-time temperature value and unit of the corresponding phase are displayed in black on a white background on the right side. This display method intuitively distinguishes the temperature status of different equipment and phases, facilitating the maintenance personnel to quickly locate abnormal points. For example, when the temperature of a certain phase is detected to exceed the preset safety threshold, the interface prompts the abnormality through color marking (such as red highlighting) or an alarm pop-up window, and at the same time records the duration and frequency of the over-temperature event, providing data support for subsequent maintenance decisions. The design not only realizes the all-round monitoring of the frequency converter temperature but also supports the backtracking of historical data and trend analysis, effectively preventing equipment failures caused by overheating and ensuring the safe and stable operation of the overhead crane drive system.

[0126] Please refer toFigure 6 , which is a schematic diagram of the monitoring of the overhead crane alarm interface provided in the embodiment of the present application, including:

[0127] Overhead crane alarm monitoring covers key parameters such as abnormal maintenance operations, risky parking events, illegal operations and equipment failures. The interface records and displays alarm events in a structured table format, including the following:

[0128] Illegal three-hand operation: For example, alarm numbers 617 and 606 record the driver's illegal behavior of operating the trolley zero position, the main trolley zero position and the main lifting zero position at the same time. The specific alarm value is described as "trolley zero position, main trolley zero position and main lifting zero position"; illegal three-hand operation means that there are three gear levers in the driver's cab. Normally, the driver can operate one gear lever with his left hand and one gear lever with his right hand. When operating illegally, the driver's elbow also operates a gear lever, which is referred to as illegal three-hand operation. Limited parking event: such as alarm numbers 604 and 605, the trigger condition is that the overhead crane runs to the preset limit area, and the alarm content is empty or the specific limit position is marked. Inverter fault: such as alarm number JT_605PLC_L1CR01CR605FKCNBQGZ, records the fault status of the auxiliary trolley inverter. The alarm value "true" indicates that the fault is activated, and "false" indicates that the fault is cleared. End beam door switch abnormality: such as alarm number JT_605PLC_L1CR01CR605YDLMKG, monitors the end beam door is not closed or abnormal opening events, the alarm value is identified by Boolean type (true / false) status.

[0129] Each alarm record contains the following fields: Alarm number: uniquely identifies the alarm event (such as 617, JT_605PLC_L1CR01CR605PKCNBQQZ); Point name: describes the alarm triggering device or location (such as "three-handle operation", "auxiliary trolley_inverter failure"); Alarm time: a timestamp accurate to milliseconds (such as 2025-02-26 15:36:38.097); Alarm content: a specific description of the abnormal operation or fault details (such as illegal operation combination, fault type).

[0130] The interface dynamically updates alarm events through a table, and supports time sorting, category filtering, and detailed viewing. For example, when "three illegal operations" are detected, the interface highlights the line and records the operation combination, allowing operation and maintenance personnel to trace the frequency and type of illegal operations; for "inverter failure", the interface synchronously marks the name of the faulty device and the time of state change, which is convenient for quickly locating the source of the fault. This design realizes real-time monitoring, structured storage, and visual analysis of abnormal events of the overhead crane, providing data support for operation and maintenance decisions, and effectively improving fault response efficiency and operational compliance management.

[0131] See also Figure 7, which is a schematic diagram of the overhead crane driver operation interface monitoring provided by the embodiment of the present application, including:

[0132] The driver operation records are statistically and displayed in real time in the form of a structured table to show the operation behaviors of the driver in the cab. The core content of the interface monitoring includes the following fields:

[0133] Operation number, which is the serial number uniquely identifying each operation event and is used for quick positioning and backtracking; operation record, which describes the specific operation type, such as "crane moving", "main hoist starting", "auxiliary trolley limit trigger", etc.; operation time, which is the timestamp accurate to the second level (such as 2025-02-26 15:36:38), recording the specific moment when the operation occurs; operation content, which details the operation parameters or states, such as "the crane speed is increased to 80%", "the main hoist load is 5 tons", "illegal triple operation (simultaneously triggering the zero positions of the crane, main trolley, and main hoist)", etc.

[0134] The interface supports dynamic update and multi-dimensional filtering functions. For example, when detecting an illegal operation (such as illegal triple operation), the interface automatically marks the record and associates it with the alarm module to generate an alarm event; the operation time field supports sorting by date range, facilitating the tracing of the operation history within a specific period; the operation content field enables quick retrieval through keyword matching (such as "illegal", "overspeed"). In addition, the interface provides an operation compliance evaluation chart, which statistically analyzes the distribution of driver operation types and the illegal frequency and displays them in a visual form to assist management personnel in optimizing operation training and standard implementation. The above design realizes the full-process monitoring and quantitative analysis of the driver's operation behaviors, effectively improving the operation safety and compliance management level.

[0135] Please refer to Figure 8 , which is a schematic diagram of the overhead crane PLC operating condition interface monitoring provided by the embodiment of the present application, including:

[0136] The liquid overhead crane ladder diagram, through a graphical interface simulating the PLC program logic, displays the core interlock conditions of the overhead crane operation in real time. The ladder diagram is presented in a PLC-like programming form, including key logic nodes such as the total start condition, total crane condition, main hoist 1 mechanism, main hoist 2 mechanism, auxiliary hoist mechanism, trolley operation condition, rectifier operation condition, etc. For example, the total start condition needs to simultaneously meet sub-conditions such as the crane being ready, the main trolley being in place, and the rectifier operation output being normal. Each sub-condition is connected in series or parallel through normally open contacts (two vertical lines) or normally closed contacts (a slant bar between two vertical lines), and the output condition is marked with curly braces to form a complete logical interlock chain.

[0137] The interface dynamically identifies the condition status through color: when all sub-conditions are met, the corresponding contacts and output conditions are displayed in green; if any sub-condition is not met (such as the trolley is not ready or the rectifier operation output is abnormal), the interlock failure is triggered, the relevant contacts turn red, and are passed to the subsequent logical nodes step by step, eventually causing the total output condition to be marked in red. For example, when the drive signal of the main hoisting mechanism 1 is detected to be abnormal, its corresponding contact immediately turns red, which affects the main hoisting total condition and the startup total condition. The interface simultaneously generates a fault alarm and locates the specific failure node, guiding the operation and maintenance personnel to quickly troubleshoot the problem.

[0138] The ladder diagram monitoring content covers the key logic of the entire process of overhead crane operation, including auxiliary driving conditions, emergency stop module output conditions, bus switch status and ISU output signals. For example, the rectifier operation conditions need to verify that the 1# and 2# rectifier outputs are normal, the bus switch closing state and the ISU signal are valid; the trolley operation conditions depend on the limit signals and speed matching of the main trolley and the auxiliary trolley. The design uses intuitive graphical expressions and real-time status feedback to enable ground operators to accurately identify the source of the fault without relying on automation professionals, shorten fault diagnosis time, and improve overhead crane operation and maintenance efficiency and system reliability.

[0139] See also Figure 9 The embodiment of the present application also provides an electronic device 300, including a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor. When the processor 320 executes the computer program 311, the steps of any method for remote monitoring of the state of an overhead crane are implemented.

[0140] Since the electronic device introduced in this embodiment is a device used to implement a remote monitoring of the state of an overhead crane in the embodiment of the present application, based on the method introduced in the embodiment of the present application, technical personnel in this field can understand the specific implementation mode of the electronic device of this embodiment and its various variations. Therefore, how the electronic device implements the method in the embodiment of the present application is not introduced in detail here. As long as the equipment used by technical personnel in this field to implement the method in the embodiment of the present application is within the scope of protection of this application.

[0141] During the specific implementation process, when the computer program 311 is executed by a processor, any implementation method in the embodiments corresponding to the first aspect can be implemented.

[0142] It should be noted that in the above embodiments, the description of each embodiment has its own emphasis, and for parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0143] Those skilled in the art should understand that the embodiments of the present application may provide a method, a system, or a computer program product. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application may take the form of a computer program product implemented on one or more computer-readable storage media that contain computer-readable program code.

[0144] The present application is described with reference to the flowcharts and / or block diagrams of methods, apparatuses (systems), and computer program products according to the embodiments of the present application. It should be understood that each flow and / or block in the flowchart and / or block diagram can be implemented by computer program instructions, and the combination of the flows and / or blocks in the flowchart and / or block diagram can also be implemented. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded computer, or other programmable data processing devices to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing devices generate means for implementing the functions specified in one Figure 1 flow or multiple flows and / or blocks Figure 1 block or multiple blocks.

[0145] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer-readable memory generate a manufactured article including instruction means, and the instruction means implements the functions specified in one Figure 1 flow or multiple flows and / or blocks Figure 1 block or multiple blocks.

[0146] These computer program instructions can also be loaded onto a computer or other programmable data processing device, so that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process, and thus the instructions executed on the computer or other programmable device provide steps for implementing the functions specified in one Figure 1 flow or multiple flows and / or blocks Figure 1 block or multiple blocks.

[0147] The embodiments of the present application also provide a computer program product, which includes computer software instructions. When the computer software instructions run on a processing device, the processing device is caused to execute Figure 3 the process of a method for remote monitoring of the overhead crane state in a corresponding embodiment.

[0148] A computer program product includes one or more computer instructions. When the computer instructions are loaded and executed on a computer, the processes or functions according to the embodiments of the present application are all or partially generated. The computer may be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions may be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions may be transmitted from one website, computer, server, or data center to another website, computer, server, or data center in a wired or wireless manner. The computer-readable storage medium may be any available medium that can be stored by a computer or a data storage device such as a server or a data center that includes one or more integrated available media. The available medium may be a magnetic medium, an optical medium, or a semiconductor medium, etc.

[0149] Those skilled in the art can clearly understand that for the convenience and brevity of description, the specific working processes of the systems, devices, and units described above can refer to the corresponding processes in the foregoing method embodiments and will not be elaborated herein.

[0150] In several embodiments provided in the present application, it should be understood that the disclosed devices, apparatuses, and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of units is only a logical function division, and there may be other division methods in actual implementation. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections to each other may be through some interfaces, and the indirect couplings or communication connections of devices or units may be in electrical, mechanical, or other forms.

[0151] The units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or distributed to multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0152] In addition, the functional units in various embodiments of the present application may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated units may be implemented in the form of hardware and / or software functional units.

[0153] When the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on such understanding, the technical solution of the present application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes several instructions for causing a computer device to execute the steps of the methods in various embodiments of the present application.

[0154] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the various embodiments of the present application.

[0155] Obviously, those skilled in the art can make various changes and deformations to this specification without departing from the spirit and scope of this specification. Thus, if these modifications and deformations of this specification fall within the scope of the claims of this specification and their equivalent technologies, this specification is also intended to include these modifications and deformations.

Claims

1. A remote monitoring system for overhead crane status, characterized in that: include: The crane programmable logic control module is used to access the crane control signal and generate the crane status data; A wireless communication network module, connected to the overhead crane programmable logic control module, for transmitting the overhead crane status data; A data acquisition module, connected to the wireless communication network module, for receiving and analyzing the state data of the overhead crane; A data storage module, connected to the data acquisition module, for converting the analyzed state data of the overhead traveling vehicle into relational data and storing the data; The remote monitoring module for the state of the overhead crane is connected to the data storage module, and is used for displaying the analyzed state data of the overhead crane, and generating the operation state information of the overhead crane based on the analyzed state data of the overhead crane.

2. The system according to claim 1, characterized in that The data storage module is a relational database, wherein the analyzed crane status data includes at least one of crane limit status data, crane motor status data, crane inverter IGBT status data, crane equipment replacement cycle status data, crane alarm status data, crane driver operation status data and crane ladder diagram status data.

3. The system according to claim 1, characterized in that The remote monitoring module for the state of the overhead travelling crane also includes: A user interaction interface of a browser / server architecture, wherein the user interaction interface is used to visually display the analyzed overhead crane status data; A logic processing unit is used to extract the operating logic conditions of the overhead crane based on the analyzed overhead crane status data; and to generate the operating status information of the overhead crane based on the operating logic conditions of the overhead crane.

4. The system according to claim 1, characterized in that The remote monitoring system for the state of the overhead crane further includes a ground engineer module, which includes: A ground engineer interaction unit, used to modify the overhead traveling crane programmable logic control program in response to an input modification instruction; The program verification unit is used to verify whether the modified program complies with the preset safety rules, and synchronize the modified program to the overhead crane programmable logic control module after the verification is passed.

5. A method for remotely monitoring the state of an overhead crane, used in the remotely monitoring state of an overhead crane according to any one of claims 1 to 4, characterized in that: The method comprises: Generate crane status data corresponding to the crane control signal through the crane programmable logic control module; Transmitting the state data of the overhead crane to a data acquisition module via a wireless communication network module; Analyzing the state data of the overhead crane by using a data acquisition module to generate analyzed state data of the overhead crane; Convert the analyzed state data of the overhead traveling vehicle into relational data, and store the data in a preset database through a data storage module; Based on the remote monitoring module of the crane status, the analyzed crane status data is displayed in real time; The overhead crane operation status statistical information is generated based on the analyzed overhead crane status data.

6. The method according to claim 5, characterized in that The analyzed crane status data includes at least one of crane limit status data, crane motor status data, crane inverter IGBT status data, crane equipment replacement cycle status data, crane alarm status data, crane driver operation status data and crane ladder diagram status data.

7. The method according to claim 6, characterized in that The analyzed crane state data includes the crane limit state data, the crane motor state data and the crane driver operation state data. The crane operation state statistical information is generated based on the analyzed crane state data, including: Based on the overhead crane limit state data, counting the number of limit position triggering and position distribution of the overhead crane within a preset period, and generating a limit position analysis report based on the number of limit position triggering and the position distribution; Extracting current data, speed data and torque data from the overhead crane motor status data, determining motor operation stability based on the current data, speed data, torque data and a preset motor health model, and generating a motor performance prompt based on the motor operation stability; According to the overhead crane driver's operation status data and preset illegal operation types, the number of illegal operations and the type of each illegal operation are identified, and based on the number of illegal operations and the type of each illegal operation, a driver operation compliance evaluation chart is generated.

8. The method according to claim 6, characterized in that Also includes: Collecting the U phase temperature parameter, the V phase temperature parameter and the W phase temperature parameter in the IGBT state data of the overhead traveling vehicle inverter; The U phase temperature parameter, the V phase temperature parameter and the W phase temperature parameter are respectively compared with the preset temperature thresholds of the corresponding phases, and when any phase temperature parameter is greater than the preset temperature threshold of the corresponding phase, a high temperature alarm signal of the corresponding phase is generated; Counting the cumulative triggering times of the high temperature alarm signal in the U phase, the V phase and the W phase within the preset time respectively; Calculate the remaining service life of the frequency converter based on the accumulated triggering times of each phase, the state data of the replacement cycle of the overhead travelling crane equipment and a preset life prediction model; Inverter maintenance prompt information is generated based on the remaining service life and the preset maintenance strategy.

9. The method according to claim 5, characterized in that Also includes: Receive modification instructions through the ground engineer module, modify the overhead crane programmable logic control program, and verify whether the modified program complies with the preset safety rules.

10. An electronic device comprising: A memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor is used to implement the steps of the method for remotely monitoring the state of an overhead crane as described in any one of claims 5 to 9 when executing the computer program stored in the memory.

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