Crawler crane rotation calibration system based on intelligent sensor

Abstract

The invention relates to the technical field of crawler crane monitoring and control, in particular to a crawler crane rotation calibration system based on an intelligent sensor, which comprises a data sensing acquisition module, a data storage module, a counterweight adjusting device and a data processing module. According to the crawler crane rotation calibration system based on the intelligent sensor, dynamic parameters and static parameters related to the rotation process of the crawler crane are monitored and collected in real time through the multi-dimensional intelligent sensor, and the real-time overturning coefficient of the whole machine is determined according to the dynamic parameters and the static parameters; an adjusting strategy of the crane is determined according to the real-time overturning coefficient, and a counterweight adjusting device of the crane in the rotary table rotating state is adjusted to adjust the gravity center of the crane in the rotating process of the crane, so that overturning of the crane is avoided or prevented, and the rotating safety and reliability of the crane are improved; and the running safety of the whole crawler crane is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of crawler crane monitoring and control, and particularly to a crawler crane slewing calibration system based on intelligent sensors. Background Art

[0002] A crawler crane is a heavy lifting equipment that relies on a crawler walking device for movement. Its chassis uses continuous crawlers instead of traditional tires, with super stability and the ability to adapt to complex terrains, belonging to the special crane category in construction machinery. Its core functions include heavy object hoisting, precise positioning, and large-range mobile operations. Rollover refers to the phenomenon that the crane topples over as a whole due to the loss of stability during operation, which is a major safety accident in the field of construction machinery. To avoid the rollover of the crane, the prior art usually improves the structure of the crane or controls the execution actions of the crane according to relevant parameters of the crane to prevent rollover.

[0003] For example, Chinese Patent Authorization Publication No. CN115092834B discloses a crawler crane and its control method, control device, and controller. The control method for the crawler crane includes: determining the vehicle weight of the crawler crane under the current working condition; determining the vehicle gravity moment parameter of the crawler crane under the current working condition; determining the overall machine overturning risk coefficient of the crawler crane under the current working condition according to the vehicle weight and the vehicle gravity moment parameter; and performing an anti-overturning control measure according to the overall machine overturning risk coefficient when the overall machine overturning risk coefficient exceeds a preset safety range. This invention can avoid removing additional counterweights even when slewing or walking or even during a small-range transfer, improving work efficiency, having a more intuitive understanding of the front and rear overturning stabilities of the whole vehicle, timely performing anti-overturning control measures, improving operation safety, and obtaining the allowable working angle range of the boom when the additional counterweight of the current working condition is completely off the ground with one key to assist operation decision-making. It can be seen that the anti-overturning control method of the prior art mainly calculates the overall machine overturning risk coefficient by detecting the static parameters of the crane and triggers the anti-overturning measures based on this coefficient. However, when the crane is actually operating, it is in a dynamic working condition. For example, the slewing motion will cause the mass distribution to change in real time, and the coupling of the load inertia force, structural centrifugal force, etc.; at the same time, operations such as acceleration and deceleration will cause the center of gravity to shift, making the overturning moment show non-linear fluctuations. Static parameters can only reflect a certain static state or instantaneous equilibrium condition and cannot capture the continuous state evolution in the dynamic process, resulting in the lag and one-sidedness of the calculated overturning risk coefficient. Therefore, the prior art methods can only be locally effective under specific static or quasi-static conditions and are difficult to cope with the overturning risk caused by the sudden change of the center of gravity under complex dynamic working conditions. Summary of the Invention

[0004] To this end, the present invention provides a swing calibration system for crawler cranes based on intelligent sensors to overcome the problem in the prior art that it can only be locally effective under specific static or quasi-static conditions and is difficult to cope with the tipping risk in complex dynamic working conditions.

[0005] To achieve the above object, the present invention provides a swing calibration system for crawler cranes based on intelligent sensors, including:

[0006] A data sensing and acquisition module, which is arranged on the crawler crane to acquire the swing angular velocity of the crane turntable, the turntable tilt angle, the hoisting height of the crane, the load weight, the counterweight position, and the included angle between the hoisting wire rope and the boom.

[0007] A data storage module, connected to the data sensing and acquisition module, for storing the various data collected by the data sensing and acquisition module.

[0008] A counterweight adjustment device, arranged at the rear of the crane installation platform, for adjusting the position of the counterweight blocks to adjust the center of gravity of the crane during the swing of the crane.

[0009] A data processing module, which is respectively connected to the data storage module and the counterweight adjustment device, for determining the dynamic tipping moment of the crane according to the angular velocity of the turntable swing, determining the static tipping moment of the crane according to the turntable tilt angle and the load weight, determining the real-time tipping coefficient of the crane according to the static tipping moment and the dynamic tipping moment, and determining the control parameters of the counterweight adjustment device during the swing of the crane according to the real-time tipping coefficient, wherein the control parameters include the intervention timing and the recovery timing of the counterweight adjustment device, the telescopic amount of the telescopic boom and the adjustment amount of the boom angle after the counterweight adjustment intervention.

[0010] Further, the data processing module determines the angular acceleration of the turntable swing and the linear acceleration of the load according to the angular velocity of the turntable swing, to determine the angular acceleration moment according to the angular acceleration of the turntable swing, determine the linear acceleration moment according to the linear acceleration of the load, determine the centrifugal moment according to the angular velocity of the turntable swing, and calculate the dynamic tipping moment of the crane according to the angular acceleration moment, the linear acceleration moment and the centrifugal moment.

[0011] Further, the data processing module determines the load static offset moment according to the turntable tilt angle, and determines the static tipping moment according to the load static offset moment and the load weight.

[0012] Further, the data processing module determines the stability moment of the crane according to the total vehicle weight of the crane and the position of the counterweight blocks, determines the total tipping moment according to the static tipping moment and the dynamic tipping moment, and determines the real-time tipping coefficient of the crane according to the total tipping moment and the stability moment.

[0013] Further, the data processing module determines whether the counterweight adjustment device intervenes according to the comparison result between the real-time overturning coefficient and the overturning threshold, where,

[0014] If the real-time overturning coefficient is greater than the first overturning threshold, it is determined that the counterweight adjustment module reaches the intervention timing, and the data processing module determines the telescopic amount of the telescopic boom and / or the adjustment amount of the angle of the telescopic boom after the counterweight adjustment based on the extreme value difference of the overturning coefficient.

[0015] Further, the data processing module is also used to determine the expected overturning coefficient according to the historical real-time overturning coefficient during the rotation of the same turntable, and determine the expected angular acceleration data according to the historical angular acceleration data during the rotation of the same turntable.

[0016] If the expected overturning coefficient is less than the first overturning threshold and the angular acceleration data of the turntable rotation at this moment is non-positive, it is determined that the counterweight adjustment module reaches the recovery timing.

[0017] Further, the data processing module is also used to determine the equivalent increased turning radius according to the included angle between the hoisting wire rope and the boom, and determine the centrifugal moment according to the angular velocity of the turntable rotation, the equivalent increased turning radius and the load weight.

[0018] Further, it further includes:

[0019] A dynamic critical threshold determination module, which is connected to the data storage module and is used to determine the maximum allowable angular velocity and the maximum allowable angular acceleration of the turntable rotation according to the hoisting height, the load weight and the equivalent increased turning radius;

[0020] An automatic adjustment module, which is respectively connected to the data storage module and the dynamic critical threshold determination module, and is used to adjust the rotation parameters of the current crane turntable according to the maximum allowable angular velocity and the maximum allowable angular acceleration.

[0021] Further, the automatic adjustment module controls the angular acceleration of the current crane turntable to be reduced to the calibrated angular acceleration according to the maximum allowable angular velocity and the maximum allowable angular acceleration, where the calibrated angular acceleration is determined according to the maximum allowable angular velocity.

[0022] Further, the data processing module uses the moving average method or the exponential smoothing method to determine the expected overturning coefficient according to the historical real-time overturning coefficient during the rotation of the same turntable.

[0023] Compared with the prior art, the beneficial effects of the present invention are that,

[0024] A swing calibration system for crawler cranes based on intelligent sensors according to the present invention monitors and collects dynamic parameters and static parameters related to the swing process of the crawler crane in real time through multi-dimensional intelligent sensors, determines the real-time tipping coefficient of the whole machine according to the dynamic parameters and static parameters, determines the adjustment strategy of the crane according to the real-time tipping coefficient, and adjusts the counterweight adjustment device of the crane in the turntable swing state to adjust the center of gravity of the crane during the swing process of the crane, thereby avoiding or preventing the crane from tipping over, improving the swing safety and reliability of the crane, and ensuring the overall vehicle operation safety of the crawler crane.

[0025] Furthermore, the present invention determines the angular acceleration of the turntable swing, the linear acceleration of the load according to the angular velocity of the turntable swing, determines the angular acceleration torque according to the angular acceleration of the turntable swing, determines the linear acceleration torque according to the linear acceleration of the load, determines the centrifugal torque according to the angular velocity of the turntable swing, and the dynamic tipping torque is the sum of the angular acceleration torque, the linear acceleration torque and the centrifugal torque, that is, the dynamic tipping torque is calculated and determined in real time according to the measurement data of the intelligent sensor, which can accurately reflect the transient load actually borne by the crane during operation. Compared with the traditional method that only depends on theoretical parameters (such as rated load, fixed leg reaction force) based on static calculation and cannot capture dynamic disturbances (such as sudden acceleration and deceleration, swing centrifugal force), the dynamic tipping torque calculation of the present invention can effectively correct such errors.

[0026] Furthermore, the static tipping torque of the present invention takes into account the influence of turntable tilt on the tipping torque. Turntable tilt will amplify the tipping torque, resulting in the center of gravity of the upper part (including the boom, counterweight, load) deviating from the theoretical vertical axis, forming an additional tipping torque. Turntable tilt will weaken the anti-tipping ability of the crane through mechanisms such as center of gravity offset and dynamic load coupling, especially when the load rate is high, the working range is large or the foundation is soft, the risk is doubled. The present invention monitors the turntable tilt angle in real time through a high-precision sensor and compensates the tipping torque through the static offset torque of the load, fully considering the tipping risk caused by the turntable tilt of the crane.

[0027] Furthermore, the traditional static method relies on the operator's experience to estimate dynamic influence factors (such as wind force coefficient, experience coefficient, adjustment factor, etc.), which is easily affected by subjective factors. The determination of the real-time tipping coefficient of the present invention, the dynamic tipping torque, the static tipping torque, the stability torque, etc. are all calculated and determined according to the data actually collected by the intelligent sensor, and the artificial deviation is eliminated by dynamic monitoring and calculating quantitative data.

[0028] Further, the present invention uses the dynamic tipping coefficient as the closed-loop control input to trigger automatic speed limit, adjust the position of the counterweight, and perform emergency braking. It actively intervenes before the critical state according to the threshold value, rather than relying solely on post-event alarms. According to the real-time changes monitored by the intelligent sensor during the slewing process of the crane, the center-of-gravity position of the crane and the slewing parameters of the slewing platform are dynamically optimized to improve the safety redundancy under complex working conditions and ensure the safe slewing operation of the crawler crane. Brief Description of the Drawings

[0029] Figure 1 is a schematic structural diagram of the system of the present invention;

[0030] Figure 2 is a flowchart for determining the comparison between the real-time tipping coefficient and the tipping threshold according to an embodiment of the present invention;

[0031] Figure 3 is a flowchart for adjusting the crane according to the expected tipping coefficient and the expected angular acceleration data according to an embodiment of the present invention;

[0032] Figure 4 is a flowchart for adjusting the crane according to the maximum allowable angular acceleration according to an embodiment of the present invention;

[0033] Figure 5 is a flowchart for adjusting the crane according to the maximum allowable angular velocity according to an embodiment of the present invention;

[0034] Figure 6 is a top view of the first state of the counterweight adjustment device of the crawler crane according to an embodiment of the present invention;

[0035] Figure 7 is a top view of the second state of the counterweight adjustment device of the crawler crane according to an embodiment of the present invention;

[0036] Figure 8 is a side view of the second state of the counterweight adjustment device of the crawler crane according to an embodiment of the present invention;

[0037] Figure 9 is a top view of the third state of the counterweight adjustment device of the crawler crane according to an embodiment of the present invention;

[0038] In the figure: 1. Crane; 2. Installation platform; 3. Counterweight adjustment device; 4. Telescopic boom; 5. Counterweight; 6. Accommodation box; 7. Base; 8. Boom. Detailed Embodiment

[0039] In order to make the objectives and advantages of the present invention clearer, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0040] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principle of the present invention and do not limit the protection scope of the present invention.

[0041] It should be noted that in the description of the present invention, the terms indicating the direction or positional relationship such as "upper", "lower", "left", "right", "inner", "outer", etc. are based on the direction or positional relationship shown in the drawings. This is only for convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention.

[0042] In addition, it should also be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0043] Please refer to Figure 1 As shown, the embodiment of the present invention provides a swing calibration system for a crawler crane based on an intelligent sensor, including:

[0044] A data sensing and acquisition module, which is arranged on the crawler crane 1 and is used to acquire the swing angular velocity and tilt angle of the crane turntable, the hoisting height of the crane, the load weight, the counterweight position, and the included angle between the hoisting steel wire rope and the boom 8;

[0045] A data storage module, which is connected to the data sensing and acquisition module and is used to store various data collected by the data sensing and acquisition module;

[0046] A counterweight adjustment device 3, which is arranged behind the crane installation platform 2 and is used to adjust the position of the counterweight block 5 to adjust the center of gravity of the crane during the swing of the crane;

[0047] A data processing module, which is respectively connected to the data storage module and the counterweight adjustment device, and is used to determine the dynamic tipping moment of the crane according to the angular velocity of the turntable swing, determine the static tipping moment of the crane according to the turntable tilt angle and the load weight, determine the real-time tipping coefficient of the crane according to the static tipping moment and the dynamic tipping moment, and determine the control parameters of the counterweight adjustment device during the swing of the crane according to the real-time tipping coefficient, wherein the control parameters include the intervention timing and recovery timing of the counterweight adjustment device, the telescopic amount of the telescopic boom and the adjustment amount of the telescopic boom angle after the counterweight adjustment intervention.

[0048] Specifically, the data sensing and acquisition module includes:

[0049] An angular velocity sensor for real-time acquisition of the angular velocity of the turntable rotation;

[0050] A distance sensor for real-time acquisition of the load height;

[0051] A force sensor for acquisition of the load weight;

[0052] An angle sensor for real-time acquisition of the included angle between the hoisting wire rope and the boom;

[0053] An inclination sensor for real-time acquisition of the turntable tilt angle;

[0054] A position sensor for real-time acquisition of the counterweight position.

[0055] A swing calibration system for crawler cranes based on intelligent sensors according to the present invention monitors and collects dynamic parameters and static parameters related to the swing process of the crawler crane in real time through multi-dimensional intelligent sensors, determines the real-time overturning coefficient of the whole machine according to the dynamic parameters and static parameters, determines the adjustment strategy of the crane according to the real-time overturning coefficient, and adjusts the counterweight adjustment device of the crane in the state of turntable swing to adjust the center of gravity of the crane during the swing process of the crane, thereby avoiding or preventing the crane from overturning, improving the swing safety and reliability of the crane, and ensuring the overall vehicle operation safety of the crawler crane.

[0056] Specifically, the data processing module determines the angular acceleration of the turntable rotation and the linear acceleration of the load according to the angular velocity of the turntable rotation, determines the angular acceleration torque according to the angular acceleration of the turntable rotation, determines the linear acceleration torque according to the linear acceleration of the load, determines the centrifugal torque according to the angular velocity of the turntable rotation, and calculates the dynamic overturning torque of the crane according to the angular acceleration torque, the linear acceleration torque and the centrifugal torque.

[0057] Specifically, the angular velocity of the turntable rotation is obtained in real time, the angular acceleration of the turntable rotation can be calculated according to the angular velocity of the turntable rotation at the previous moment and the next moment. The angular velocity and angular acceleration of the turntable rotation are the same as those of the load. The linear acceleration of the load can be calculated according to the angular acceleration and the turning radius (arm of force). The linear acceleration torque can be calculated according to the linear acceleration of the load, the load weight and the hoisting height. The angular acceleration torque can be calculated according to the angular acceleration, the load weight and the turning radius. The centrifugal torque can be calculated according to the angular velocity, the load weight and the turning radius.

[0058] It can be understood that for the radius of gyration, it can be directly measured by separately setting a distance sensor, or it can be obtained by calculation through geometric relationships based on data such as the load height, the angle between the boom and the turntable, and the length of the boom.

[0059] The present invention determines the angular acceleration of the turntable rotation and the linear acceleration of the load according to the angular velocity of the turntable rotation, determines the angular acceleration moment according to the angular acceleration of the turntable rotation, determines the linear acceleration moment according to the linear acceleration of the load, determines the centrifugal moment according to the angular velocity of the turntable rotation, and the dynamic tipping moment is the sum of the angular acceleration moment, the linear acceleration moment and the centrifugal moment. That is, the dynamic tipping moment is calculated and determined in real time according to the measurement data of the intelligent sensor, which can accurately reflect the transient load actually borne by the crane during operation. Compared with the traditional method that only depends on theoretical parameters (such as rated load, fixed outrigger reaction force) based on static calculation and cannot capture dynamic disturbances (such as sudden acceleration and deceleration, rotational centrifugal force), the dynamic tipping moment calculation of the present invention can effectively correct such errors.

[0060] Specifically, the data processing module determines the static offset moment of the load according to the tilt angle of the turntable, and determines the static tipping moment according to the static offset moment of the load and the load weight.

[0061] Specifically, the static offset moment of the load is determined by the tilt angle of the turntable, and the static moment of the load is first calculated according to the load weight.

[0062] The calculation method of the static moment of the load is the product of the load weight, the acceleration due to gravity, and the radius of gyration. The radius of gyration is the radius of gyration when the load is stationary before the crane rotates, that is, the horizontal distance from the load or the center of gravity of the load to the tipping fulcrum when the load is stationary. In actual operation, it can be simplified to the horizontal distance from the load suspension point to the turntable rotation center.

[0063] The static offset moment of the load is the product of the static moment of the load and the sine value of the tilt angle of the turntable. After obtaining the static offset moment of the load, the static offset moment of the load and the static moment of the load are added to obtain the static tipping moment.

[0064] The static tipping moment of the present invention takes into account the influence of the turntable tilt on the tipping moment. The turntable tilt will amplify the tipping moment, causing the center of gravity of the upper part of the vehicle (including the boom, counterweight, load) to deviate from the theoretical vertical axis, forming an additional tipping moment. The turntable tilt will weaken the anti-tipping ability through mechanisms such as center of gravity offset and dynamic load coupling, especially when the load rate is high, the working range is large, or the foundation is soft, the risk is doubled. The present invention monitors the tilt angle of the turntable in real time through a high-precision sensor, and dynamically compensates the tipping moment through the static offset moment of the load, fully considering the tilt and tipping risk of the crane.

[0065] Specifically, the data processing module determines the stability moment of the crane based on the vehicle weight of the crane and the position of the counterweight, determines the total overturning moment based on the static overturning moment and the dynamic overturning moment, and determines the real-time overturning coefficient of the crane based on the total overturning moment and the stability moment.

[0066] Specifically, the stability moment is related to the vehicle weight of the crane, the weight and position of the counterweight. The vehicle weight includes the weights of all structures of the crane chassis (tracks and mounting platform), slewing platform, boom, etc. (excluding the counterweight), the counterweight weight is the total mass of the known additional counterweights, the counterweight position is the horizontal distance from the center of the counterweight to the outermost side of the track on the slewing side of the boom, the center of gravity of the vehicle (when the counterweight is not included) can be determined according to the design drawings or measured data, and the vehicle center of gravity position is the horizontal distance from the center of gravity of the vehicle to the outermost side of the track on the slewing side of the boom.

[0067] The stability moment is the sum of the stability moment generated by the vehicle weight and the stability moment generated by the counterweight. The stability moment generated by the vehicle weight is the product of the vehicle weight and the vehicle center of gravity position (the horizontal distance from the center of gravity of the vehicle to the outermost side of the track on the slewing side of the boom), and the stability moment generated by the counterweight is the product of the counterweight weight and the counterweight position (the horizontal distance from the center of the counterweight to the outermost side of the track on the slewing side of the boom).

[0068] Specifically, the total overturning moment is the sum of the static overturning moment and the dynamic overturning moment.

[0069] The real-time overturning coefficient of the crane is the total overturning moment / (total overturning moment + stability moment).

[0070] Traditional static methods rely on the operator's experience to estimate dynamic influence factors (such as wind force coefficient, experience coefficient, adjustment factor, etc.), which are easily affected by subjective factors. For the determination of the real-time overturning coefficient of the present invention, the dynamic overturning moment, static overturning moment, stability moment, etc. are all calculated and determined based on the actual data collected by intelligent sensors, and the artificial deviation is eliminated by dynamically monitoring and calculating the quantified data.

[0071] As an implementation manner, when calculating and determining the stability moment, the influence of the slewing platform tilt angle needs to be considered for the vehicle center of gravity position and the counterweight position. Therefore, in this implementation manner, the vehicle center of gravity position and the counterweight position are corrected. Specifically, the correction value of the vehicle center of gravity position is the vehicle center of gravity position multiplied by the cosine value of the slewing platform tilt angle, and the correction value of the counterweight position is the counterweight position multiplied by the cosine value of the slewing platform tilt angle.

[0072] Specifically, the data processing module determines whether the counterweight adjustment device intervenes according to the comparison result between the real-time overturning coefficient and the overturning threshold, where

[0073] If the real-time tipping coefficient is greater than the first tipping threshold, it is determined that the counterweight adjustment module reaches the intervention timing, and the data processing module determines the telescopic amount of the telescopic boom and / or the adjustment amount of the angle of the telescopic boom after the counterweight adjustment is intervened based on the extreme difference of the tipping coefficients.

[0074] Please refer to Figure 2 , and the determination process of the data processing module based on the comparison between the real-time tipping coefficient and the tipping threshold includes:

[0075] If the real-time tipping coefficient is less than or equal to the first tipping threshold, the crane continues to perform the slewing operation;

[0076] If the real-time tipping coefficient is greater than the first tipping threshold and less than the second tipping threshold, the extreme difference of the tipping coefficients is determined based on the real-time tipping coefficient within a calculation period,

[0077] If the extreme difference of the tipping coefficients is less than or equal to the tipping coefficient extreme difference threshold, the crane is controlled to adjust the angle of the telescopic boom of the counterweight adjustment device,

[0078] If the extreme difference of the tipping coefficients is greater than the tipping coefficient extreme difference threshold, the angular acceleration change rate is determined based on the angular acceleration data within a calculation period,

[0079] If the angular acceleration change rate is less than or equal to the angular acceleration change rate threshold, the crane is controlled to adjust the telescopic amount of the telescopic boom of the counterweight adjustment device,

[0080] If the angular acceleration change rate is greater than the angular acceleration change rate threshold, the crane is controlled to reduce the angular velocity of the turntable slewing;

[0081] If the real-time tipping coefficient is greater than or equal to the second tipping threshold, the crane turntable slewing is controlled to stop urgently.

[0082] In one embodiment, the first tipping threshold is 0.7 and the second tipping threshold is 0.9.

[0083] In another embodiment, the first tipping threshold is 0.6 and the second tipping threshold is 0.8.

[0084] Specifically, please refer to Figures 6 - 9 , the counterweight adjustment device includes a telescopic boom 4, a receiving box 6, and a base 7. The receiving box is arranged on the base and the receiving box can rotate relative to the base. One end of the telescopic boom is connected to the receiving box, and a counterweight block is connected to the other end of the telescopic boom. In Figure 6 In the shown state one, the counterweight adjustment device has not reached the intervention timing. At this time, the telescopic boom is in a fully retracted state, and the counterweight block is located in the receiving box. As Figures 7 - 8 , Figure 9The figures respectively show the state diagrams of the telescopic boom extending and the accommodating box rotating to make the telescopic boom rotate. By controlling the extension and rotation of the telescopic boom, the position of the counterweight is adjusted, and thus the overall center of gravity of the crane and the counterweight is adjusted (i.e., the real-time tipping coefficient is changed or adjusted).

[0085] As an implementation manner, controlling the angle of the telescopic boom of the counterweight adjustment device of the crane specifically includes: determining the included angle between the telescopic boom of the counterweight adjustment device and the projection of the boom on the horizontal plane, and controlling the accommodating box of the counterweight adjustment device to rotate according to the included angle so that the telescopic boom rotates until the projections of the telescopic boom and the boom on the horizontal plane are on the same straight line (forming an angle of 180°).

[0086] As an implementation manner, controlling the telescopic amount of the telescopic boom of the counterweight adjustment device of the crane specifically includes: controlling the telescopic boom to extend outwards until the real-time tipping coefficient is less than or equal to the first tipping threshold or the telescopic length of the telescopic boom reaches the maximum value.

[0087] As an implementation manner, the tipping coefficient range threshold is determined according to the tipping coefficient range difference of the slewing processes without tipping during the historical slewing of the crane. During each slewing of the crane, the real-time tipping coefficient is determined, recorded, and saved in real time according to the data monitored by the intelligent sensor. After the first N slewing operations of the crane are completed, for the n slewing processes without tipping (n ≤ N), the mean value of the tipping coefficient range differences in the n slewing processes is taken to form a set, and the maximum value in the set is taken as the tipping coefficient range threshold. According to this tipping coefficient range threshold, the (N + 1)-th slewing calibration control is performed. After completion, if no tipping occurs, the mean value of the tipping coefficient range during this slewing of the crane is added to the above set for update, and then the tipping coefficient range threshold is re-determined.

[0088] The determination method of the angular acceleration change rate threshold is the same as that of the tipping coefficient range threshold, and will not be elaborated here.

[0089] The present invention uses the dynamic tipping coefficient as the closed-loop control input to trigger automatic speed limit, adjust the position of the counterweight (the length and / or angle of the telescopic boom), and emergency braking, and actively intervenes before the critical state according to the threshold, rather than only relying on post-alarm. According to the real-time changes monitored by the intelligent sensor during the slewing process of the crane, the center of gravity position of the crane and the slewing parameters of the turntable are dynamically optimized, the safety redundancy under complex working conditions is improved, and the slewing operation safety of the crawler crane is ensured.

[0090] Specifically, the data processing module is further configured to determine the expected tipping coefficient according to the historical real-time tipping coefficient during the same turntable slewing process, and determine the expected angular acceleration data according to the historical angular acceleration data during the same turntable slewing process.

[0091] If the expected overturning coefficient is less than the first overturning threshold and the expected angular acceleration data corresponding to this moment is non-positive, it is determined that the counterweight adjustment module reaches the recovery timing.

[0092] As an implementation manner, when it is determined that the counterweight adjustment module reaches the recovery timing, the telescopic arm of the counterweight adjustment device is controlled to contract to retract the counterweight block into the accommodation box.

[0093] Please refer to Figure 3 , the data processing module is also used to adjust the crane according to the expected overturning coefficient and the expected angular acceleration data, including:

[0094] If the expected overturning coefficient is greater than or equal to the second overturning threshold and the expected angular acceleration data corresponding to this moment is positive, the rotation of the crane turntable is controlled to stop urgently.

[0095] As an implementation manner, the data processing module uses the moving average method to determine the expected overturning coefficient according to the historical real-time overturning coefficient data during the same turntable rotation process.

[0096] As another implementation manner, the data processing module uses the exponential smoothing method to determine the expected overturning coefficient according to the historical real-time overturning coefficient data during the same turntable rotation process.

[0097] As an implementation manner, the data processing module uses the moving average method to determine the expected angular acceleration according to the historical angular acceleration data during the same turntable rotation process.

[0098] As another implementation manner, the data processing module uses the exponential smoothing method to determine the expected angular acceleration according to the historical angular acceleration data during the same turntable rotation process.

[0099] The present invention predicts the real-time overturning coefficient and angular acceleration data, anticipates the future overturning trend, and triggers an emergency stop signal in advance, breaking through the lag of the traditional solution that only relies on the current instantaneous data. At the same time, it combines the composite judgment of the overturning coefficient (stability index) and the angular acceleration (dynamic load). When the overturning coefficient ≥ the threshold and the angular acceleration is positive, it indicates that the crane is in a superimposed dangerous state of high overturning risk and active accelerating rotation, avoiding mis-triggering by a single parameter (such as the case where the overturning coefficient is high but the risk is reduced during the deceleration stage).

[0100] Specifically, the data processing module is also used to determine the equivalent increased turning radius according to the included angle between the hoisting steel wire rope and the boom, and determine the centrifugal moment according to the angular velocity of the turntable rotation, the equivalent increased turning radius, and the load weight.

[0101] When the crane is slewing, due to inertia or external force (acceleration), the load will swing back and forth to form a swing angle. It is necessary to re-determine the slewing radius to calculate the centrifugal force. The size of the swing angle can be equivalently calculated according to the included angle between the hoisting wire rope and the boom. Specifically, the swing angle = the included angle between the hoisting wire rope and the boom obtained in real time - the included angle between the hoisting wire rope and the boom when the load is stationary. The equivalent increased slewing radius is the slewing radius when the load is stationary plus the product of the slewing radius when the load is stationary and the sine value of the swing angle. After determining the equivalent increased slewing radius, the centrifugal moment is determined according to the moment formula.

[0102] Specifically, it further includes:

[0103] A dynamic critical threshold determination module, which is connected to the data storage module, and is used to determine the maximum allowable angular velocity and maximum allowable angular acceleration of the turntable slewing according to the hoisting height, load weight and equivalent increased slewing radius;

[0104] An automatic adjustment module, which is respectively connected to the data storage module and the dynamic critical threshold determination module, and is used to adjust the slewing parameters of the current crane turntable according to the maximum allowable angular velocity and the maximum allowable angular acceleration.

[0105] As an implementation manner, the maximum allowable angular velocity and the maximum allowable angular acceleration can be determined according to the angular velocity and angular acceleration of the slewing process without tipping over during the historical crane slewing process (controlling other parameters to be the same, such as hoisting height, load weight, turntable tilt angle, etc.). Specifically, taking the maximum allowable angular velocity as an example, take the maximum value of the angular velocity of the slewing process without tipping over during the historical crane slewing process.

[0106] As an implementation manner, the maximum allowable angular velocity and the maximum allowable angular acceleration can be calculated according to the following formula:

[0107]

[0108] Specifically, the automatic adjustment module controls the angular acceleration of the current crane turntable to be reduced to the calibration angular acceleration according to the maximum allowable angular velocity and the maximum allowable angular acceleration, where the calibration angular acceleration is determined according to the maximum allowable angular velocity.

[0109] Please refer to Figure 4 and Figure 5 , more specifically: when the turntable slewing is in the acceleration stage or the deceleration stage, control the angular acceleration of the turntable slewing not to exceed 80% of the maximum allowable angular acceleration. When the angular velocity of the turntable slewing is greater than or equal to the maximum allowable angular velocity, control the turntable slewing to decelerate.

[0110] The present invention controls the rotation of the turntable according to the maximum allowable angular velocity and the maximum allowable angular acceleration. Limiting the maximum angular velocity can directly reduce the centrifugal force during rotation, avoiding imbalance or overturning of the whole machine caused by excessive centrifugal force. Limiting the maximum angular acceleration can avoid the inertial torque generated by sudden start and stop, reduce the instantaneous impact on the crawler and the turntable structure, and at the same time can reduce the amplitude of the swing angle, enhancing the operation stability and accuracy.

[0111] The present invention realizes a trinity architecture of dynamic perception, intelligent calculation and active control during the rotation process of the crane through intelligent sensors, upgrading the anti-overturning of the crane from "passive response" to "active defense", achieving a qualitative breakthrough in safety.

[0112] So far, the technical solution of the present invention has been described in combination with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0113] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A slewing calibration system for crawler cranes based on intelligent sensors, characterized in that, Comprising: A data sensing and acquisition module, which is arranged on the crawler crane and is used to acquire the rotational angular velocity of the crane turntable, the tilt angle of the turntable, the hoisting height of the crane, the load weight, the counterweight position, and the included angle between the hoisting wire rope and the boom; A data storage module, connected to the data sensing and acquisition module, for storing various data collected by the data sensing and acquisition module; A counterweight adjustment device, arranged at the rear of the crane installation platform, for adjusting the position of the counterweight block to adjust the center of gravity of the crane during the rotation of the crane; A data processing module, which is respectively connected to the data storage module and the counterweight adjustment device, and is used to determine the dynamic tipping moment of the crane according to the rotational angular velocity of the turntable rotation, determine the static tipping moment of the crane according to the turntable tilt angle and the load weight, determine the real-time tipping coefficient of the crane according to the static tipping moment and the dynamic tipping moment, and determine the control parameters of the counterweight adjustment device during the rotation of the crane according to the real-time tipping coefficient, wherein the control parameters include the intervention timing and the return timing of the counterweight adjustment device, the telescopic amount of the telescopic boom and the adjustment amount of the telescopic boom angle after the counterweight adjustment intervention.

2. The crawler crane slewing calibration system based on intelligent sensors according to claim 1, wherein The data processing module determines the angular acceleration of the turntable rotation and the linear acceleration of the load according to the rotational angular velocity of the turntable rotation, so as to determine the angular acceleration moment according to the angular acceleration of the turntable rotation, determine the linear acceleration moment according to the linear acceleration of the load, determine the centrifugal moment according to the rotational angular velocity of the turntable rotation, and calculate the dynamic tipping moment of the crane according to the angular acceleration moment, the linear acceleration moment and the centrifugal moment.

3. The crawler crane slewing calibration system based on intelligent sensors according to claim 1, wherein, The data processing module determines the load static offset moment according to the turntable tilt angle, and determines the static tipping moment according to the load static offset moment and the load weight.

4. The crawler crane slewing calibration system based on intelligent sensors according to claim 1, wherein The data processing module determines the stability moment of the crane according to the total vehicle weight of the crane and the position of the counterweight block, determines the total tipping moment according to the static tipping moment and the dynamic tipping moment, and determines the real-time tipping coefficient of the crane according to the total tipping moment and the stability moment.

5. The crawler crane slewing calibration system based on intelligent sensors according to claim 4, characterized in that, The data processing module determines whether the counterweight adjustment device intervenes according to the comparison result between the real-time tipping coefficient and the tipping threshold, wherein, If the real-time tipping coefficient is greater than the first tipping threshold, it is determined that the counterweight adjustment module reaches the intervention timing, and the data processing module determines the telescopic amount of the telescopic boom and / or the adjustment amount of the telescopic boom angle after the counterweight adjustment intervention based on the extreme difference of the tipping coefficients.

6. The crawler crane slewing calibration system based on intelligent sensors according to claim 5, characterized in that, The data processing module is also used to determine the expected tipping coefficient according to the historical real-time tipping coefficients during the rotation of the same turntable, and determine the expected angular acceleration data according to the historical angular acceleration data during the rotation of the same turntable, If the expected tipping coefficient is less than the first tipping threshold, and the angular acceleration data of the turntable rotation at this moment is non-positive, it is determined that the counterweight adjustment module reaches the return timing.

7. The crawler crane slewing calibration system based on intelligent sensors according to claim 2, wherein The data processing module is also used to determine the equivalent increased turning radius according to the included angle between the hoisting wire rope and the boom, and determine the centrifugal moment according to the rotational angular velocity of the turntable rotation, the equivalent increased turning radius and the load weight.

8. The crawler crane slewing calibration system based on intelligent sensors according to claim 7, characterized in that, Also comprising: A dynamic critical threshold determination module, which is connected to the data storage module and is used to determine the maximum allowable angular velocity and maximum allowable angular acceleration of the turntable rotation according to the lifting height, load weight, and equivalent increased slewing radius; An automatic adjustment module, which is respectively connected to the data storage module and the dynamic critical threshold determination module, and is used to adjust the rotation parameters of the current crane turntable according to the maximum allowable angular velocity and the maximum allowable angular acceleration.

9. The crawler crane slewing calibration system based on intelligent sensors according to claim 8, wherein, The automatic adjustment module controls the rotational angular acceleration of the current crane turntable to be reduced to a calibrated angular acceleration according to the maximum allowable angular velocity and the maximum allowable angular acceleration, wherein the calibrated angular acceleration is determined according to the maximum allowable angular velocity.

10. The crawler crane slewing calibration system based on intelligent sensors according to claim 6, characterized in that, The data processing module uses the moving average method or the exponential smoothing method to determine the expected tipping coefficient according to the historical real-time tipping coefficient during the same turntable rotation.

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