Remote control device and method for anti-collision system of crane

Abstract

The invention provides a remote control device and method for a crane anti-collision system. The remote control device comprises a scanning module, a detection module, a control module, a remote terminal, a sensor module, an early warning module and a power adjusting module. The scanning module measures an optical distance to a target by using a plurality of laser scanners; the detection module defines a three-dimensional reference area detection target and classifies the target; and the control module receives the detection result, starts a risk avoiding program and realizes remote communication and parameter adjustment, and an internal data storage unit, an algorithm processing unit and an instruction output unit work cooperatively. And the remote terminal is used for real-time data viewing and remote control. The sensor module collects operation data of the crane, the early warning module sends out early warning of different levels, and the power adjusting module adjusts a power system. The method comprises the steps of distance measurement, target detection, data acquisition, risk assessment and classification, remote control risk avoiding and data feedback updating. Through multi-module cooperation and multi-step cooperation, high-precision detection and reliable remote control of the operation environment of the crane are achieved, the operation safety of the crane is effectively improved, and collision accidents are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of crane safety control, and particularly to a remote control device and method for a crane anti-collision system. Background Art

[0002] In modern industrial production and logistics transportation, cranes are widely used. Especially in places such as ports, construction sites, and large factories, cranes undertake a large number of tasks of handling and loading / unloading goods. However, due to the complex operating environment, such as the presence of numerous containers, moving vehicles, and personnel in ports, and various building materials and construction equipment in construction sites, cranes are extremely prone to collision accidents during operation. Once a collision occurs, it will not only cause damage to the crane itself, but also may lead to damage to goods and casualties, bringing huge economic losses and adverse social impacts to enterprises.

[0003] At present, there are many deficiencies in the existing crane anti-collision systems. On the one hand, existing measuring devices, such as ultrasonic sensors, have limited resolution and it is difficult to accurately judge whether obstacles in front of the crane will continuously block the traveling path, resulting in a high false alarm rate in complex environments; measurements based on laser sensors usually can only measure single points or single lines, or the sensor needs to be continuously moved, which weakens the durability of the measurement scheme in vibrating environments and various weather conditions, and the moving parts need to be maintained regularly due to natural wear, increasing the use cost and downtime. On the other hand, most of the existing anti-collision systems lack an efficient remote control function. When a potential collision risk is detected, on-site operators may not be able to make accurate responses in a timely manner, or may not be able to effectively avoid collision accidents due to operational errors. Therefore, it is of great practical significance to develop a crane anti-collision system with high-precision detection and reliable remote control functions. Summary of the Invention

[0004] The present invention provides a remote control device and method for a crane anti-collision system to solve the problems of low intelligence and low control efficiency of existing control devices, realizing high-precision detection of the crane operating environment and reliable remote control, effectively improving the safety of crane operations and reducing the occurrence of collision accidents.

[0005] The present invention provides a remote control device for a crane anti-collision system, including: A scanning module, installed on the crane, including a plurality of laser scanners, for measuring the optical distance between the crane and the target object along the first traveling direction, and the laser scanners are installed on the front end, side, or side of the lifting element of the crane; A detection module, connected to the scanning module; A control module, the control module is connected to the detection module, receives the results of the detection module, and starts the risk avoidance program unit when a collision risk is detected; The remote terminal is connected to the control module through a wireless communication network and is used to view the crane operation status, scanning data, target information and reference area data in real time, and provide an operation interface to remotely control the crane operation and set the control module parameters; A sensor module connected to the control module; The early warning module is connected to the control module. The control module sends out early warning signals of different levels through the early warning module according to the detected collision risk level, including changes in sound intensity, frequency, light color, and flashing frequency; The power regulation module is connected with the control module and the crane power system. The control module adjusts the output power and torque of the crane power system through the power regulation module according to the collision risk and operation requirements.

[0006] Preferably, the laser scanner comprises a 3D laser scanner or a LiDAR scanner.

[0007] Preferably, the hazard avoidance program unit includes sending out an audio signal, sending out a light signal, reducing the moving speed of the crane, stopping the crane urgently, lifting the load, changing the direction of the crane, and moving the load laterally.

[0008] Preferably, the sensor module includes a speed sensor, an acceleration sensor, and an angle sensor, which are respectively used to monitor the operating speed, acceleration, and angle information of each component of the crane in real time, and transmit the monitoring data to the control module.

[0009] Preferably, the control module includes a data storage unit, an algorithm processing unit and an instruction output unit, and the data storage unit, the algorithm processing unit and the instruction output unit are connected in sequence, the data storage unit receives and stores data from the scanning module, the detection module and the sensor module, the algorithm processing unit calls the data of the data storage unit for calculation, and the instruction output unit converts the calculation results of the algorithm processing unit into control instructions and sends them to the early warning module, the power adjustment module and the various execution components of the crane.

[0010] Preferably, a remote control method for a crane anti-collision system comprises the following steps: A. Distance measurement: using a laser scanner installed in a scanning module on the crane to measure the optical distance between the crane and the target in the first travel direction; B. Target detection: The detection module uses the scanning module to define a three-dimensional reference area consisting of the surface of the cargo loading and unloading area and its vertical tolerance, and detects targets in the cargo loading and unloading area based on the difference between the scanning height and the reference area height; C. Data acquisition: The sensor module continuously collects the operating speed, acceleration of the crane, and the angular information of each component, and transmits the data to the data storage unit of the control module; D. Risk assessment and classification: The algorithm processing unit of the control module classifies the target based on the distance data of the scanning module, the target detection results of the detection module, and the operating data of the sensor module, and evaluates the collision risk level; E. Remote control and collision avoidance: When a target is detected and a collision risk is judged, the instruction output unit of the control module activates the corresponding collision avoidance procedure according to the risk level, and sends the information to the remote terminal. The operator remotely controls the crane to perform the collision avoidance operation through the remote terminal. If the operator does not operate, the control module automatically executes the collision avoidance procedure according to the preset priority; At the same time, the control module issues warning signals of different levels through the warning module according to the risk level, and adjusts the output power and torque of the crane power system through the power adjustment module; F. Data feedback and update: The scanning module, the detection module, and the sensor module continuously collect data and feedback it to the data storage unit of the control module. The remote terminal updates the display content in real time, and the algorithm processing unit of the control module dynamically updates the reference area and the control strategy according to the new data.

[0011] Preferably, in step D, a target with a larger size and a faster moving speed is determined as a high risk, and a target with a smaller size and stationary is determined as a low risk; At the same time, combining the operating speed, acceleration, and angular information of each component of the crane itself, the collision risk is comprehensively evaluated.

[0012] Preferably, in step F, the control module adjusts the detection sensitivity, the priority of the collision avoidance procedure, and the output parameters of the power system according to the new data. Advantageous effects

[0013] (1) Through the cooperation of multiple modules and multiple steps, the present invention realizes high-precision detection of the crane operating environment and reliable remote control, effectively improves the operating safety of the crane, and reduces the occurrence of collision accidents.

[0014] (2) The present invention adopts a scanning module composed of multiple laser scanners, combined with a unique installation layout and scanning angle design, which can comprehensively and accurately measure the optical distance between the crane and the target object. The multi-angle, multi-directional scanning and the setting of the beam overlapping area effectively avoid the monitoring blind area and timely discover potential collision targets. The detection module can accurately identify the target and evaluate the risk with the help of accurate three-dimensional reference area definition and advanced RANSAC method. Subsequently, the control module activates a rich set of collision avoidance procedures, such as sound and light alarms, speed reduction, stop, adjustment of load position, etc., greatly reducing the probability of collision accidents and ensuring the safety of personnel lives and equipment and property.

[0015] (3) In the present invention, the remote terminal is connected to the control module through wireless communication. The operator can remotely and real-time view key data such as the operating status of the crane, scanned data, target information, etc. With the help of the operation interface, the operator can remotely and precisely control operations such as the start, stop, speed adjustment, and direction change of the crane, and can also flexibly set the parameters of the control module. In the face of a complex and dangerous operating environment, the operator does not need to be on-site, can quickly make a response, and timely handle emergencies, greatly improving the convenience and precision of operation, and reducing the accident risk caused by difficult or incorrect on-site operations. The above description is only an overview of the technical solution of the embodiment of the present invention. In order to be able to more clearly understand the technical means of the embodiment of the present invention, it can be implemented according to the content of the specification. And in order to make the above and other purposes, features, and advantages of the embodiment of the present invention more obvious and understandable, the following specifically gives the specific implementation manners of the present invention. Brief Description of the Drawings

[0016] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the following will briefly introduce the drawings required for the description of the embodiment. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0017] Figure 1 It is the control principle block diagram of the present invention; Figure 2 It is the principle block diagram of the control module of the present invention; Figure 3 It is the working flow chart of the present invention; Description of the reference numerals: scanning module 1, laser scanner 2, detection module 3, control module 4, remote terminal 5, wireless communication network 6, sensor module 7, warning module 8, power adjustment module 9, crane power system 10, speed sensor 11, acceleration sensor 12, angle sensor 13, data storage unit 14, algorithm processing unit 15, instruction output unit 16. Specific Embodiments

[0018] To make the purpose, technical solution, 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 drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the protection scope of the present invention.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field to which this invention belongs; the terms used in the description of the application herein are for the purpose of describing specific embodiments only and are not intended to limit the present invention; the terms "including" and "having" and any variations thereof in the description and claims of the present invention and the accompanying drawings are intended to cover non-exclusive inclusion.

[0020] To enable those skilled in the art to better understand the solution of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0021] Please refer to Figures 1-3 , the present invention discloses a remote control device for a crane anti-collision system, including: A scanning module 1, installed on the crane, includes a plurality of laser scanners 2. The laser scanner 2 includes a 3D laser scanner or a LiDAR scanner, and is used to measure the optical distance between the crane and the target object along the first traveling direction. The laser scanner is installed at the front end, side or side of the lifting element of the crane; the light beam is conical, with an opening angle of 20 degrees - 180 degrees, there is an overlapping area between the light beams, and it can scan in the downward diagonal direction; A detection module 3, connected to the scanning module 1; a three-dimensional reference area covering the plane of the cargo handling area and its vertical tolerance range is defined by means of the scanning module, the target is detected based on the difference between the scanning height and the height of the reference area, the reference surface is defined by the RANSAC method, and a classifier for classifying the target according to the target size and / or motion state is equipped; the vertical tolerance means that when the crane transports goods with a specified maximum allowable mass at a specific maximum allowable acceleration or deceleration, the laser scanner measures from the surface of the cargo handling area, and at least 95% of the measured values are within the specified tolerance range. At least part of the cargo handling area is a storage area managed by the crane or a container handling area for handling and storing ISO containers. The detection module can identify the downward deviation of the reference area in this area and the reference points or reference surfaces inside, and assist the crane in navigation.

[0022] A control module 4, the control module 4 is connected to the detection module 3, receives the results of the detection module, and starts the hazard avoidance program unit when a collision risk is detected; the hazard avoidance program unit includes emitting an audio signal, emitting a light signal, reducing the moving speed of the crane, stopping the crane urgently, lifting the load, changing the direction of the crane, and laterally moving the load. It also has a remote communication function, can send the target position information to other cranes, the terminal control system or the monitoring system, and can adjust the detection and processing methods of the target in the public area according to the settings of the remote terminal; The remote terminal 5 is connected to the control module 4 via a wireless communication network 6 and is used to view the operating status of the crane, scan data, target information, and reference area data in real time, and provide an operation interface for remotely controlling the operation of the crane and setting the parameters of the control module; The sensor module 7 is connected to the control module 4; the sensor module 7 includes a speed sensor 11, an acceleration sensor 12, and an angle sensor 13, which are respectively used to monitor the operating speed, acceleration, and angle information of each component of the crane in real time, and transmit the monitored data to the control module; The warning module 8 is connected to the control module 4. The control module issues warning signals of different levels through the warning module according to the detected collision risk level, including changes in sound intensity, frequency, and light color and flashing frequency; The power adjustment module 9 is connected to the control module 4 and the crane power system 10. The control module adjusts the output power and torque of the crane power system through the power adjustment module according to the collision risk and operating requirements.

[0023] In the present invention, the control module 4 includes a data storage unit 14, an algorithm processing unit 15, and an instruction output unit 16. The data storage unit 14, the algorithm processing unit 15, and the instruction output unit 16 are connected in sequence. The data storage unit receives and stores the data of the scanning module, the detection module, and the sensor module. The algorithm processing unit calls the data in the data storage unit for calculation. The instruction output unit converts the calculation result of the algorithm processing unit into a control instruction and sends it to the warning module, the power adjustment module, and each execution component of the crane.

[0024] Working principle: A remote control method for a crane anti-collision system includes the following steps: A. Distance measurement: Using a laser scanner in the scanning module installed on the crane, measure the optical distance between the crane and the target in the first traveling direction; B. Target detection: The detection module defines a three-dimensional reference area composed of the surface of the cargo handling area and its vertical tolerance with the help of the scanning module, and detects the target in the cargo handling area based on the height difference between the scanning height and the reference area height; C. Data acquisition: The sensor module collects the operating speed, acceleration, and angle information of each component of the crane in real time, and transmits the data to the data storage unit of the control module; D. Risk assessment and classification: The algorithm processing unit of the control module classifies the target and evaluates the collision risk level according to the distance data of the scanning module, the target detection result of the detection module, and the operating data of the sensor module; E. Remote control and risk avoidance: When a target is detected and a collision risk is judged, the instruction output unit of the control module activates the corresponding risk avoidance procedure according to the risk level, and sends the information to the remote terminal. The operator remotely controls the crane to perform risk avoidance operations through the remote terminal. If the operator does not operate, the control module automatically executes the risk avoidance procedure according to the preset priority. At the same time, the control module issues warning signals of different levels through the warning module according to the risk level, and adjusts the output power and torque of the crane power system through the power adjustment module. F. Data feedback and update: The scanning module, detection module, and sensor module continuously collect data and feedback it to the data storage unit of the control module. The remote terminal updates the display content in real time. The algorithm processing unit of the control module dynamically updates the reference area and control strategy according to the new data.

[0025] Among them, in step D, a target with a larger size and a faster moving speed is determined as a high-risk target, and a target with a smaller size and being stationary is determined as a low-risk target. At the same time, combined with the running speed, acceleration, and angle information of each component of the crane itself, the collision risk is comprehensively evaluated.

[0026] In step F, the control module adjusts the detection sensitivity, the priority of the risk avoidance procedure, and the output parameters of the power system according to the new data.

[0027] In an actual application scenario, taking a port container crane as an example, during the process of the crane loading and unloading containers, the laser scanner in the scanning module continuously scans the surrounding environment. For example, when the crane moves towards the container stacking area, the laser scanner measures the optical distances to containers, other cranes, terminal facilities, and possible personnel or vehicles.

[0028] The detection module defines a three-dimensional reference area for the cargo loading and unloading area according to the data obtained by the scanning module. Suppose at a certain moment, the detection module discovers a target whose measured height exceeds the reference area. After being judged by the classifier, this target is a moving small vehicle and belongs to a medium-risk target.

[0029] After receiving the information from the detection module, the control module immediately activates the risk avoidance procedure, issues audio and optical signal alarms, and at the same time reduces the moving speed of the crane. Meanwhile, the control module sends the position information of the target to the remote terminal. After seeing the alarm on the remote terminal, the operator remotely controls the crane to further change the direction through the operation interface, so as to avoid the traveling route of the small vehicle.

[0030] Throughout the process, the scanning module and the detection module continuously collect data, and the remote terminal updates and displays the operating status of the crane, the surrounding environment information, etc. in real time. If new targets are detected or the environment changes subsequently, the control module and the remote terminal will make corresponding adjustments and controls based on the new data to ensure the safe operation of the crane.

[0031] The present invention adopts a scanning module composed of multiple laser scanners, combined with a unique installation layout and scanning angle design, which can comprehensively and accurately measure the optical distance between the crane and the target object. The multi-angle and multi-directional scanning and the setting of the beam overlapping area effectively avoid the monitoring blind area and timely detect potential collision targets. The detection module can accurately identify the targets and evaluate the risks by means of precise three-dimensional reference area definition and advanced RANSAC method. Subsequently, the control module activates a rich set of risk avoidance procedures, such as audible and visual alarms, speed reduction, stop, adjustment of the load position, etc., greatly reducing the probability of collision accidents and ensuring the safety of personnel lives and equipment and property. In the present invention, the remote terminal is connected to the control module through wireless communication. The operator can remotely and real-time view key data such as the operating status of the crane, scanning data, target information, etc. With the help of the operation interface, the operator can remotely and precisely control operations such as the start, stop, speed adjustment, and direction change of the crane, and can also flexibly set the parameters of the control module. In the face of a complex and dangerous operating environment, the operator does not need to be on-site, can quickly make responses, and timely handle emergencies, greatly improving the convenience and accuracy of operation and reducing the accident risks caused by difficult or incorrect on-site operations.

[0032] In summary, through the cooperation of multiple modules and multiple steps, the present invention realizes high-precision detection of the crane operating environment and reliable remote control, effectively improving the operating safety of the crane and reducing the occurrence of collision accidents.

[0033] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention 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 recorded in the foregoing embodiments, or perform equivalent replacements for 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 invention.

Claims

1. A remote control device for a crane anti-collision system, characterized in that: include: A scanning module (1) is installed on the crane and comprises a plurality of laser scanners (2) for measuring the optical distance between the crane and a target object along a first travel direction, wherein the laser scanners are installed on the front end, side or side of a lifting element of the crane; A detection module (3) connected to the scanning module (1); A control module (4), the control module (4) being connected to the detection module (3), receiving a result of the detection module, and activating a risk avoidance program unit when a collision risk is detected; A remote terminal (5) is connected to the control module (4) via a wireless communication network (6) and is used to view the crane operation status, scanning data, target information and reference area data in real time, and to provide an operation interface for remotely controlling the crane operation and setting control module parameters; A sensor module (7) connected to the control module (4); An early warning module (8) is connected to the control module (4), and the control module sends out early warning signals of different levels through the early warning module according to the detected collision risk level, including changes in sound intensity and frequency, and light color and flashing frequency; The power regulating module (9) is connected to the control module (4) and the crane power system (10), and the control module adjusts the output power and torque of the crane power system through the power regulating module according to the collision risk and operation requirements.

2. The remote control device of a crane anti-collision system according to claim 1, characterized in that: The laser scanner (2) includes a 3D laser scanner or a LiDAR scanner.

3. The remote control device of a crane anti-collision system according to claim 1, characterized in that: The risk avoidance program unit includes sending out audio signals, sending out light signals, reducing the moving speed of the crane, stopping the crane urgently, lifting the load, changing the direction of the crane, and moving the load laterally.

4. A remote control device for a crane anti-collision system according to claim 1, characterized in that: The sensor module (7) comprises a speed sensor (11), an acceleration sensor (12), and an angle sensor (13), which are respectively used to monitor the operating speed, acceleration, and angle information of each component of the crane in real time, and transmit the monitoring data to the control module.

5. The remote control device of a crane anti-collision system according to claim 1, characterized in that: The control module (4) comprises a data storage unit (14), an algorithm processing unit (15) and an instruction output unit (16), wherein the data storage unit (14), the algorithm processing unit (15) and the instruction output unit (16) are connected in sequence, the data storage unit receives and stores data from the scanning module, the detection module and the sensor module, the algorithm processing unit calls the data of the data storage unit for calculation, and the instruction output unit converts the calculation result of the algorithm processing unit into a control instruction and sends it to the early warning module, the power adjustment module and the various execution components of the crane.

6. A remote control method for a crane anti-collision system, characterized in that: The following steps are involved: A. Distance measurement: using a laser scanner installed in a scanning module on the crane to measure the optical distance between the crane and the target in the first travel direction; B. Target detection: The detection module uses the scanning module to define a three-dimensional reference area consisting of the surface of the cargo loading and unloading area and its vertical tolerance, and detects targets in the cargo loading and unloading area based on the difference between the scanning height and the reference area height; C. Data acquisition: The sensor module collects the running speed, acceleration and angle information of each component of the crane in real time, and transmits the data to the data storage unit of the control module; D. Risk assessment and classification: The algorithm processing unit of the control module classifies the targets and assesses the collision risk level based on the distance data of the scanning module, the target detection results of the detection module, and the operation data of the sensor module; E. Remote control and risk avoidance: When a target is detected and it is determined that there is a collision risk, the command output unit of the control module starts the corresponding risk avoidance program according to the risk level and sends the information to the remote terminal. The operator remotely controls the crane to perform risk avoidance operations through the remote terminal. If the operator does not operate, the control module automatically executes the risk avoidance program according to the preset priority. At the same time, the control module sends different levels of warning signals through the warning module according to the risk level, and adjusts the output power and torque of the crane power system through the power adjustment module; F. Data feedback and update: The scanning module, detection module and sensor module continuously collect data and feed it back to the data storage unit of the control module. The remote terminal updates the display content in real time. The algorithm processing unit of the control module dynamically updates the reference area and control strategy according to the new data.

7. The remote control method of a crane anti-collision system according to claim 6, characterized in that: In step D, targets that are larger in size and move faster are judged as high risk, and targets that are smaller in size and stationary are judged as low risk; at the same time, the collision risk is comprehensively assessed in combination with the crane's own operating speed, acceleration and angle information of each component.

8. The remote control method of a crane anti-collision system according to claim 6, characterized in that: In step F, the control module adjusts the detection sensitivity, the priority of the hazard avoidance program and the output parameters of the power system according to the new data.

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