Subway gantry crane control system based on PLC wireless control and monitoring

Abstract

The invention discloses a subway gantry crane control system based on PLC wireless control and monitoring. The subway gantry crane control system comprises a master station PLC control module, a slave station PLC control module, a first wireless communication module, a second wireless communication module, a sensor module, a data acquisition and processing module, a video monitoring module, a human-computer interaction interface and a UPS module. The master station PLC control module, the first wireless communication module and the UPS module are all arranged in an electrical room of the metro gantry crane, the slave station PLC control module, the second wireless communication module and the data acquisition and processing module are all arranged in an electrical cabinet of a hoisting trolley of the metro gantry crane, and the sensor modules are respectively arranged on the hoisting trolley and a mobile cart of the metro gantry crane. The video monitoring modules are respectively arranged on a hoisting trolley of the metro gantry crane and in a cab, the man-machine interaction interface is arranged in the cab, and the electrical room and the cab are both arranged on a main beam platform of the metro gantry crane. The system has the advantages that wiring is simple, installation and transition are convenient, troubleshooting is convenient, and labor is saved.

Description

Technical Field

[0001] The present invention relates to the technical field of subway gantry cranes, and more particularly to a subway gantry crane control system based on PLC wireless control and monitoring. Background Art

[0002] A subway gantry crane, also known as a subway gantry or subway crane, is an important device used in subway construction, maintenance, and repair. In traditional subway gantry crane control systems, the power and control parts between the electrical room and the hoisting trolley usually adopt a wired connection method. The disadvantages of this connection method are as follows: (1) The power line and the control line (including communication) are mixedly wired, which is troublesome in construction and inconvenient in maintenance, and is prone to signal interference, affecting the stability of the whole machine system; (2) When the equipment is transferred for installation and commissioning, the wiring is difficult and the fault troubleshooting is complex. Summary of the Invention

[0003] The purpose of the present invention is to provide a subway gantry crane control system based on PLC wireless control and monitoring to solve the technical problems existing in the background art.

[0004] To achieve the above object, the technical solution adopted by the present invention is as follows:

[0005] A subway gantry crane control system based on PLC wireless control and monitoring includes a master station PLC control module, a slave station PLC control module, a first wireless communication module, a second wireless communication module, a sensor module, a data acquisition and processing module, a video monitoring module, a human-machine interface, and a UPS uninterruptible power supply module;

[0006] The master station PLC control module, the first wireless communication module, and the UPS uninterruptible power supply module are all arranged in the electrical room of the subway gantry crane. The slave station PLC control module, the second wireless communication module, and the data acquisition and processing module are all arranged in the electrical cabinet of the hoisting trolley of the subway gantry crane. The sensor module is separately arranged on the hoisting trolley and the moving trolley of the subway gantry crane. The video monitoring module is separately arranged on the hoisting trolley and in the driver's cab of the subway gantry crane. The human-machine interface is arranged in the driver's cab. The electrical room and the driver's cab are both arranged on the main beam platform of the subway gantry crane;

[0007] The master station PLC control module is electrically connected to the first wireless communication module, the video monitoring module, and the human-machine interface respectively. The slave station PLC control module is electrically connected to the second wireless communication module and the data acquisition and processing module respectively. The first wireless communication module is communicatively connected to the second wireless communication module. The sensor module is electrically connected to the data acquisition and processing module. The UPS uninterruptible power supply module is electrically connected to the master station PLC control module, the slave station PLC control module, the first wireless communication module, the second wireless communication module, the data acquisition and processing module, the video monitoring module, and the human-machine interface respectively.

[0008] Further, the sensor module includes a trolley position sensor, a gantry position sensor, and a weight sensor;

[0009] The trolley position sensor is installed on the running wheel of the hoisting trolley and is electrically connected to the data acquisition and processing module, and is used to detect the moving position of the hoisting trolley;

[0010] The gantry position sensor is installed on the running wheel of the moving gantry and is electrically connected to the data acquisition and processing module, and is used to detect the position of the entire subway gantry crane;

[0011] The weight sensor is installed on the bearing seat at the end of the crane drum shaft and is electrically connected to the data acquisition and processing module, and is used to detect the load condition of the subway gantry crane.

[0012] Further, the data acquisition and processing module includes a first encoder pulse collector, a second encoder pulse collector, and a voltage-current converter. The first encoder pulse collector is electrically connected to the trolley position sensor and the slave station PLC control module respectively. The second encoder pulse collector is electrically connected to the gantry position sensor and the slave station PLC control module respectively. The voltage-current converter is electrically connected to the weight sensor and the slave station PLC control module respectively.

[0013] Further, the video monitoring module includes a video monitoring camera and a video monitoring display. The video monitoring camera is installed on the hoisting trolley and is communicatively connected to the first wireless communication module and electrically connected to the UPS uninterruptible power supply module respectively. The video monitoring display is arranged in the driver's cab and is electrically connected to the master station PLC control module and the UPS uninterruptible power supply module respectively.

[0014] Further, the master station PLC control module adopts a PLC programmable logic controller of Siemens S7 series or Mitsubishi FX series.

[0015] Further, the slave station PLC control module adopts a PLC programmable logic controller of Siemens S7 series or Mitsubishi FX series.

[0016] Further, the first wireless communication module is a Wi-Fi module, a 4G / 5G module, a Bluetooth module, a Zigbee module or a LoRa module.

[0017] Further, the second wireless communication module is a Wi-Fi module, a 4G / 5G module, a Bluetooth module, a Zigbee module or a LoRa module.

[0018] Compared with the prior art, the advantages of the present invention are as follows:

[0019] (1) The safety and reliability of the overall control system of the subway gantry crane are improved, and the frequency conversion interference problem of the traditional control system is solved.

[0020] (2) The wiring path is optimized. Dozens of wires of the sliding contact line of the traditional control system can be optimized into 1 power line, which is convenient for installation and transfer, simple in wiring, convenient for troubleshooting, and saves labor. Description of the Drawings

[0021] In order to more clearly illustrate the technical solutions in this embodiment, the following will briefly introduce the drawings required for the description of the embodiment. Obviously, the following described drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0022] Figure 1 It is the schematic diagram of the subway gantry crane control system based on PLC wireless control and monitoring of the present invention;

[0023] Figure 2 It is the application embodiment of the subway gantry crane control system based on PLC wireless control and monitoring of the present invention;

[0024] Description of the reference numerals: 1, master station PLC control module; 2, slave station PLC control module; 3, first wireless communication module; 4, second wireless communication module; 5, sensor module; 501, trolley position sensor; 502, gantry position sensor; 503, weight sensor; 6, data acquisition and processing module; 601, first encoder pulse collector; 602, second encoder pulse collector; 603, voltage and current converter; 7, video surveillance camera; 8, video surveillance display; 9, human-machine interface; 10, UPS uninterruptible power supply module; 11, electrical room; 12, hoisting trolley electrical cabinet; 13, hoisting trolley; 14, moving gantry; 15, bearing seat at the end of the crane drum shaft; 16, driver's cab; 17, main beam platform. Detailed Embodiments

[0025] To make the objectives, technical solutions and advantages of the present invention more clear, the following will, in conjunction with the accompanying drawings in the embodiments of the present invention, clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are some, rather than all, of the embodiments of the present invention. Components of the embodiments of the present invention usually described and shown in the accompanying drawings here can be arranged and designed in various different configurations.

[0026] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed present invention, but merely represents selected embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0027] In the description of the embodiments of the present invention, it should be noted that unless otherwise clearly specified and limited, if the terms "set", "installed", "connected", "connected" are used, they 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 components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0028] The following further describes the present invention in conjunction with the accompanying drawings:

[0029] Refer to Figure 1 and Figure 2 A subway gantry crane control system based on PLC wireless control and monitoring provided by the present invention includes a master station PLC control module 1, a slave station PLC control module 2, a first wireless communication module 3, a second wireless communication module 4, a sensor module 5, a data acquisition and processing module 6, a video monitoring module, a human-machine interface 9, and a UPS uninterruptible power supply module 10;

[0030] Among them, the master station PLC control module 1, the first wireless communication module 3, and the UPS uninterruptible power supply module 10 are all set in the electrical room 11 of the subway gantry crane. The slave station PLC control module 2, the second wireless communication module 4, and the data acquisition and processing module 6 are all set in the hoisting trolley electrical cabinet 12 of the subway gantry crane. The sensor module 5 is separately arranged on the hoisting trolley 13 and the moving trolley 14 of the subway gantry crane. The video monitoring module is separately arranged on the hoisting trolley 13 of the subway gantry crane and in the driver's cab 16. The human-machine interface 9 is set in the driver's cab 16. The electrical room 11 and the driver's cab 16 are both set on the main beam platform 17 of the subway gantry crane;

[0031] Among them, the master station PLC control module 1 is electrically connected to the first wireless communication module 3, the video monitoring module, and the human-machine interface 9 respectively. The slave station PLC control module 2 is electrically connected to the second wireless communication module 4 and the data acquisition and processing module 6 respectively. The first wireless communication module 3 is communicatively connected to the second wireless communication module 4. The sensor module 5 is electrically connected to the data acquisition and processing module 6. The UPS uninterruptible power supply module 10 is electrically connected to the master station PLC control module 1, the slave station PLC control module 2, the first wireless communication module 3, the second wireless communication module 4, the video monitoring module, and the human-machine interface 9 respectively;

[0032] Among them, the function of the master station PLC control module 1 is to control the operation of the entire system. The function of the slave station PLC control module 2 is to control the operation of the hoisting trolley 13 and the sensor module 5. The function of the sensor module 5 is to monitor the working state of the subway gantry crane in real time. The function of the data acquisition and processing module 6 is to be responsible for data acquisition, processing, and storage. The function of the video monitoring module is to remotely monitor the subway gantry crane. The function of the human-machine interface 9 is for operators to interact with the system. The function of the UPS uninterruptible power supply module 10 is to ensure that the system can continue to supply stable power to the system after a power outage, so that the video monitoring module remains online. The function of the hoisting trolley 13 is to be responsible for the hoisting operation in the vertical direction. The function of the moving trolley 14 is to be responsible for the movement in the horizontal direction.

[0033] Specifically, in the present invention, the master station PLC control module 1 can adopt a Siemens S7 series or Mitsubishi FX series PLC programmable logic controller. For example: S7-200, S7-300, or S7-400; PLC programmable logic controllers of the FX3G, FX3U, FX2N, FX1N, or FX1S series.

[0034] Specifically, in the present invention, the slave station PLC control module 2 can adopt a Siemens S7 series or Mitsubishi FX series PLC programmable logic controller. For example: S7-200, S7-300, or S7-400; PLC programmable logic controllers of the FX3G, FX3U, FX2N, FX1N, or FX1S series.

[0035] Specifically, in the present invention, the first wireless communication module 3 can be a Wi-Fi module, 4G / 5G module, Bluetooth module, Zigbee module, or LoRa module.

[0036] Specifically, in the present invention, the second wireless communication module 4 can be a Wi-Fi module, 4G / 5G module, Bluetooth module, Zigbee module, or LoRa module.

[0037] Specifically, in the present invention, the sensor module 5 includes a trolley position sensor 501, a gantry position sensor 502, and a weight sensor 503. Among them, the trolley position sensor 501 is installed on the running wheels of the hoisting trolley 13 and is electrically connected to the data acquisition and processing module 6, and is used to detect the moving position of the hoisting trolley 13. The gantry position sensor 502 is installed on the running wheels of the moving gantry 14 and is electrically connected to the data acquisition and processing module 6, and is used to detect the position of the entire subway gantry crane. The weight sensor 503 is installed on the bearing seat at the end of the crane drum shaft 15 and is electrically connected to the data acquisition and processing module 6, and is used to detect the load condition of the subway gantry crane.

[0038] Specifically, in some other embodiments, in order to facilitate monitoring the traveling speeds of the hoisting trolley 13 and the moving gantry 14, the sensor module 5 further includes a trolley speed sensor and a gantry speed sensor. The trolley speed sensor is installed on the main shaft of the driving motor or the main shaft of the running wheel of the hoisting trolley 13 and is used to detect the traveling speed of the hoisting trolley 13. The gantry speed sensor is installed on the main shaft of the driving motor or the main shaft of the running wheel of the moving gantry 14 and is used to detect the traveling speed of the entire subway gantry crane.

[0039] Specifically, in some other embodiments, in order to facilitate monitoring the temperature conditions of the electrical equipment of the subway gantry crane, the sensor module 5 further includes a temperature sensor, and the temperature sensors are respectively arranged on each motor of the subway gantry crane (such as: on the driving motor of the hoisting trolley 13 and on the driving motor of the moving gantry 14).

[0040] Specifically, in some other embodiments, in order to facilitate monitoring the tilt angle condition of the entire subway gantry crane, the sensor module 5 further includes an inclination sensor, and the inclination sensor is arranged on the chassis of the subway gantry crane.

[0041] Specifically, in the present invention, the data acquisition and processing module 6 includes a first encoder pulse collector 601, a second encoder pulse collector 602, and a voltage-current converter 603. Among them, the first encoder pulse collector 601 is electrically connected to the trolley position sensor 501 and the slave station PLC control module 2 respectively. The second encoder pulse collector 602 is electrically connected to the gantry position sensor 502 and the slave station PLC control module 2 respectively. The voltage-current converter 603 is electrically connected to the weight sensor 503 and the slave station PLC control module 2 respectively. Among them, the function of the first encoder pulse collector 601 is to collect the real-time pulses of the trolley traveling encoder (i.e., the trolley position sensor 501) and convert them into distance values in meters. The function of the second encoder pulse collector 602 is to collect the real-time pulses of the gantry traveling encoder (i.e., the gantry position sensor 502) and convert them into distance values in meters. The function of the voltage-current converter 603 is to convert the millivolt signal of the weight sensor 503 into a current signal that can be collected by the slave station PLC control module 2.

[0042] Specifically, in the present invention, the video monitoring module includes a video monitoring camera 7 and a video monitoring display 8. Among them, the video monitoring camera 7 is installed on the hoisting trolley 13 and is communicatively connected to the first wireless communication module 3 and electrically connected to the UPS uninterruptible power supply module 10 respectively. The video monitoring display 8 is arranged in the driver's cab 16 and is electrically connected to the master station PLC control module 1 and the UPS uninterruptible power supply module 10 respectively. The video monitoring camera 7 is used to capture the running state of the hoisting mechanism in the hoisting trolley and transmit the captured image to the video monitoring display 8 in the driver's cab 16 through wireless signals.

[0043] Specifically, in the present invention, the human-machine interaction interface 9 includes a display interface, an operation interface, and an alarm prompt module. Among them, the display interface is used to display the real-time status and historical data of the subway gantry crane. The operation interface is used to provide operation buttons and indicator lights for easy operation by the operator. The alarm prompt module is used to send out sound and / or light prompts to the outside world when the system detects an abnormal situation.

[0044] Finally, it should be noted that the above are only embodiments of the present invention, and do not limit the patent scope of the present invention accordingly. Any equivalent structural or equivalent process transformation made by using the content of the specification and drawings of the present invention, or directly or indirectly applied to other related technical fields, shall be equally included in the patent protection scope of the present invention.

Claims

1. A subway door crane control system based on PLC wireless control and monitoring, characterized in that: It includes a master station PLC control module (1), a slave station PLC control module (2), a first wireless communication module (3), a second wireless communication module (4), a sensor module (5), a data acquisition and processing module (6), a video monitoring module, a human-machine interface (9), and a UPS uninterruptible power supply module (10); The master station PLC control module (1), the first wireless communication module (3), and the UPS uninterruptible power supply module (10) are all arranged in the electrical room (11) of the subway gantry crane. The slave station PLC control module (2), the second wireless communication module (4), and the data acquisition and processing module (6) are all arranged in the hoisting trolley electrical cabinet (12) of the subway gantry crane. The sensor module (5) is separately arranged on the hoisting trolley (13) and the moving trolley (14) of the subway gantry crane. The video monitoring module is separately arranged on the hoisting trolley (13) and in the driver's cab (16) of the subway gantry crane. The human-machine interface (9) is arranged in the driver's cab (16). The electrical room (11) and the driver's cab (16) are both arranged on the main beam platform (17) of the subway gantry crane; The master station PLC control module (1) is electrically connected to the first wireless communication module (3), the video monitoring module, and the human-machine interface (9) respectively. The slave station PLC control module (2) is electrically connected to the second wireless communication module (4) and the data acquisition and processing module (6) respectively. The first wireless communication module (3) is communicatively connected to the second wireless communication module (4). The sensor module (5) is electrically connected to the data acquisition and processing module (6). The UPS uninterruptible power supply module (10) is electrically connected to the master station PLC control module (1), the slave station PLC control module (2), the first wireless communication module (3), the second wireless communication module (4), the video monitoring module, and the human-machine interface (9) respectively.

2. The subway door crane control system based on PLC wireless control and monitoring according to claim 1, characterized in that: The sensor module (5) includes a trolley position sensor (501), a trolley position sensor (502), and a weight sensor (503); The trolley position sensor (501) is installed on the running wheel of the hoisting trolley (13) and is electrically connected to the data acquisition and processing module (6) for detecting the moving position of the hoisting trolley (13); The trolley position sensor (502) is installed on the running wheel of the moving trolley (14) and is electrically connected to the data acquisition and processing module (6) for detecting the position of the entire subway gantry crane; The weight sensor (503) is installed on the bearing seat at the end of the crane drum shaft (15) and is electrically connected to the data acquisition and processing module (6) for detecting the load condition of the subway gantry crane.

3. The subway door crane control system based on PLC wireless control and monitoring according to claim 1, characterized in that: The data acquisition and processing module (6) includes a first encoder pulse collector (601), a second encoder pulse collector (602), and a voltage-current converter (603). The first encoder pulse collector (601) is electrically connected to the trolley position sensor (501) and the slave station PLC control module (2) respectively. The second encoder pulse collector (602) is electrically connected to the gantry position sensor (502) and the slave station PLC control module (2) respectively. The voltage-current converter (603) is electrically connected to the weight sensor (503) and the slave station PLC control module (2) respectively.

4. The subway door crane control system based on PLC wireless control and monitoring according to claim 1, wherein: The video monitoring module includes a video monitoring camera (7) and a video monitoring display (8). The video monitoring camera (7) is installed on the hoisting trolley (13), and is communicatively connected to the first wireless communication module (3) and electrically connected to the UPS uninterruptible power supply module (10) respectively. The video monitoring display (8) is arranged in the driver's cab (16), and is electrically connected to the master station PLC control module (1) and the UPS uninterruptible power supply module (10) respectively.

5. The subway door crane control system based on PLC wireless control and monitoring according to any one of claims 1 to 4, characterized in that: The master station PLC control module (1) uses a PLC programmable logic controller of the Siemens S7 series or the Mitsubishi FX series.

6. The subway gantry crane control system based on PLC wireless control and monitoring according to any one of claims 1 to 4, characterized in that: The slave station PLC control module (2) uses a PLC programmable logic controller of the Siemens S7 series or the Mitsubishi FX series.

7. The subway gantry crane control system based on PLC wireless control and monitoring according to any one of claims 1 to 4, characterized in that: The first wireless communication module (3) is a Wi-Fi module, a 4G / 5G module, a Bluetooth module, a Zigbee module, or a LoRa module.

8. The subway door crane control system based on PLC wireless control and monitoring according to any one of claims 1 to 4, characterized in that: The second wireless communication module (4) is a Wi-Fi module, a 4G / 5G module, a Bluetooth module, a Zigbee module, or a LoRa module.

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