Intelligent duct piece crane for tunnel

Abstract

The invention relates to the technical field of duct piece cranes, and discloses a tunnel intelligent duct piece crane which comprises a maintenance pool used for storing and preserving prefabricated duct pieces. The binocular vision system is used for scanning the poses of the duct pieces in the maintenance pool and generating three-dimensional coordinates; the tail end of the modularized telescopic suspension arm is integrated with a vacuum suction cup and mechanical claw composite grabbing mechanism; the six-dimensional force sensor is arranged at the joint of the modularized telescopic suspension arm, the vacuum chuck and the mechanical claw composite grabbing mechanism and is used for detecting load torque and collision signals in real time; and the central controller is internally provided with an industrial PLC and an ROS algorithm module, and is used for receiving data and controlling hoisting path planning and execution. According to the method, the three-dimensional coordinates of the segment are accurately obtained through the binocular vision system, and automatic calibration and path planning are achieved; a six-dimensional force sensor is adopted to monitor load torque and collision signals in real time, and hoisting stability and load balance are ensured; accurate positioning, anti-collision control and intelligent path control are achieved, and hoisting parameters are automatically adjusted.

Description

Technical Field

[0001] The present invention relates to the technical field of segment cranes, and in particular to an intelligent segment crane for a tunnel. Background Art

[0002] Currently, shield construction is widely used in urban rail transit and municipal tunnel construction. As the core components of tunnel structures, the efficiency and safety of segment hoisting directly impact the overall project progress and quality. In the complex, narrow, and ever-changing tunnel environment, traditional hoisting methods are increasingly exposed to bottlenecks such as delayed response and difficulty in human-machine collaboration. To ensure construction continuity and nighttime operation capabilities, construction units urgently need to introduce intelligent and automated control technologies into their hoisting equipment to enhance its adaptability and operational capabilities.

[0003] Currently, the common segment cranes in the industry mainly rely on manual control systems for operation, with the boom driven by a simple electric motor to achieve horizontal and vertical lifting. Some equipment is equipped with cameras and display terminals to assist manual observation and positioning grasping. The positioning method usually uses a reference line combined with manual correction for adjustment, and the clamps are mostly mechanical one-way opening and closing structures. During the lifting process, the operator relies on experience to adjust the grasping posture and path correction. Sensors are mostly used for limit protection or prompting, and lack real-time linkage feedback. The overall lifting process is still based on "observation-judgment-operation", with a loose control process and limited automatic adjustment capabilities.

[0004] Existing lifting equipment still has difficulty in achieving real-time recognition of the segment posture and intelligent generation of trajectories, and lifting path deviations are prone to occur. Positioning methods are limited by site layout and lighting conditions. Under obstructed or highly reflective conditions, positioning accuracy fluctuates significantly and stability is insufficient. Controlled actions are mostly preset instructions or rely on manual fine-tuning. They lack the ability to automatically correct based on load feedback, and are prone to insufficient clamping force when the segment is eccentric or offset. The sensing system is dispersed and has poor coordination, making it difficult to build an integrated safety monitoring system. In addition, the control logic is simple and cannot actively respond to and dynamically compensate for construction disturbances. Especially in high-altitude or inclined lifting scenarios, errors accumulate significantly, and there are certain operational risks and quality hazards. Summary of the Invention

[0005] In response to the shortcomings of the existing technology, the present invention provides an intelligent tunnel segment crane, which solves the problems of low positioning accuracy, unstable lifting operation and unbalanced load of traditional cranes in complex environments.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: an intelligent tunnel segment crane, comprising a curing pool, a built-in circulating cooling water system and segment coordinate identification tags, for storing and preserving prefabricated segments, with a moving assembly provided on the top;

[0007] A binocular vision system, installed inside the gantry crane system, is used to scan the position of the segments in the curing tank and generate three-dimensional coordinates;

[0008] Modular telescopic boom with a telescopic travel of 0-15m and an integrated vacuum suction cup and mechanical claw composite grasping mechanism at the end;

[0009] A six-dimensional force sensor is installed at the connection between the modular telescopic boom and the composite gripping mechanism of the vacuum suction cup and mechanical claw to detect load torque and collision signals in real time;

[0010] The central controller has a built-in industrial PLC and ROS algorithm module, receives data from the binocular vision system and six-dimensional force sensor, and controls the hoisting path planning and execution.

[0011] Preferably, the mobile component includes a carrying platform, and two mobile bases are provided on both sides of the bottom of the carrying platform. The mobile bases are slidably connected to the top of the side wall of the curing pool, and protective fences are installed around the top of the carrying platform.

[0012] Preferably, the door machine system includes a central controller, and movable support legs are provided on both sides of the bottom of the central controller, and movable inner rails are provided on both sides of the interior of the supporting platform, and the bottom of the movable support legs is slidably connected to the inside of the movable inner rails.

[0013] Preferably, the modular telescopic boom is driven by a high-precision ball screw with a telescopic positioning accuracy of ±1 mm, and the end is detachably connected to a folding support frame, which contacts the tunnel side wall to form a triangular stable structure after unfolding.

[0014] Preferably, the vacuum suction cup and mechanical claw composite grasping mechanism includes:

[0015] Vacuum suction cup group, arranged in the center area of ​​the pipe segment, with a suction force of ≥5kN;

[0016] Adaptive mechanical grippers are symmetrically distributed on the edge of the segment, with a clamping angle adjustable by ±15° and a clamping force that dynamically matches the segment weight.

[0017] The anti-sway system uses the gyroscope feedback at the top of the boom to control the servo motor to compensate for the displacement of the steel cable, so that the swing amplitude of the pipe segment is ≤3mm.

[0018] Preferably, an intelligent tunnel segment crane further includes a multimodal safety monitoring system, the system comprising:

[0019] The wind speed sensor is installed on the top of the central controller. When the wind speed is greater than 10m / s, lifting operations are prohibited;

[0020] The two moving trolleys are equipped with a weight sensor on one side of the top to detect the weight they bear; the two moving trolleys are equipped with a height sensor on the other side of the top to monitor the height of the crane in real time;

[0021] The odometer wheel is used to calculate the displacement of the mobile vehicle.

[0022] Preferably, a binocular vision system is installed on one side opposite to the other of the two movable support legs, and an electric slide rail is provided inside the movable support legs, and the binocular vision system is slidably connected inside the electric slide rail.

[0023] Preferably, an industrial computer is installed on each opposite side between the two movable support legs, and a video display is provided on the industrial computer. The industrial computer has a built-in ROS algorithm module for receiving binocular vision system and six-dimensional force sensor data, generating lifting path control instructions and outputting them to the industrial PLC controller.

[0024] Preferably, an absolute encoder and an anti-collision ranging sensor are installed at the bottom of the movable support leg, and laser reflection targets are set every 1m on both sides of the track. The central controller achieves a door machine positioning error of ≤±2mm by fusing the encoder pulse signal with the laser ranging data.

[0025] Preferably, the anti-collision ranging sensor communicates with the central controller, and triggers a three-level deceleration strategy when it detects that the obstacle distance is less than a predetermined value.

[0026] The present invention provides an intelligent tunnel segment crane with the following beneficial effects:

[0027] 1. This invention uses a binocular vision system to scan and identify the position of pipe segments in real time, accurately acquiring the three-dimensional coordinates of the segments and automatically calibrating the gripping position. This visual recognition technology not only improves the accuracy of lifting operations but also adapts to segments of varying shapes and sizes, maintaining stable gripping performance in complex environments. The binocular vision system, connected to a central controller, provides real-time position data on the segments, supporting lifting path planning and ensuring that the lifting operation remains on track.

[0028] 2. This invention uses a six-dimensional force sensor to detect load torque and collision signals generated during the lifting process in real time. By coordinating with the central controller's feedback control system, it can automatically adjust the lifting path to prevent equipment damage or unstable lifting caused by collisions or overloads. The sensor also monitors the force applied to the segments, achieving load balancing and ensuring uniform grip and balance during the lifting process, thereby avoiding lifting errors caused by uneven force distribution.

[0029] 3. This invention utilizes an absolute encoder and anti-collision ranging sensors to achieve precise positioning control. By integrating the encoder's pulse signal with laser ranging data, the system can control the door crane's positioning error to within ±2mm, ensuring accuracy during the hoisting process. The anti-collision ranging sensor measures the distance between obstacles and the crane in real time during operation and automatically triggers a deceleration strategy when encountering obstacles, effectively avoiding safety issues caused by collisions.

[0030] 4. The central controller of this invention incorporates a built-in industrial PLC and ROS algorithm module, capable of receiving data from a binocular vision system and a six-dimensional force sensor, generating lifting path control instructions in real time, and outputting them to the industrial PLC controller. This system's intelligent control enables the lifting process to be completed smoothly without human intervention, improving operational efficiency and safety. The system can also automatically adjust lifting parameters based on environmental changes and operational requirements, adapting to different work scenarios.

[0031] 5. The multiple sensors and feedback control system of the present invention work together to achieve precise control and real-time adjustment during the lifting process. This not only ensures the stability of the lifting operation, but also reduces human error during the operation, improving the overall accuracy and safety of the operation. Especially in complex or confined working environments, the equipment's flexibility and automatic adjustment capabilities enable the lifting task to be completed smoothly, avoiding accidents caused by changes in the external environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 A perspective view of the present invention;

[0033] Figure 2 It is a structural schematic diagram of the movable support leg of the present invention;

[0034] Figure 3 for Figure 2 A magnified view of middle A;

[0035] Figure 4 It is a structural diagram of the industrial control computer of the present invention;

[0036] Figure 5 for Figure 4 Magnified view of B.

[0037] Among them, 1. Maintenance pool; 2. Mobile components; 201. Mobile base; 202. Carrying platform; 203. Protective fence; 3. Door machine system; 301. Central controller; 302. Mobile support legs; 303. Mobile inner rail; 4. Crane; 401. Modular telescopic boom; 402. Vacuum suction cup and mechanical claw composite grasping mechanism; 4021. Vacuum suction cup group; 4022. Adaptive mechanical claw; 5. Binocular vision system; 6. Industrial computer; 7. Wind speed sensor; 8. Mobile trolley; 9. Weight sensor; 10. Height sensor; 11. Taxi wheel; 12. Six-dimensional force sensor. DETAILED DESCRIPTION

[0038] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the present specification. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0039] Please see the attached Figure 1 -Attached Figure 5 The embodiment of the present invention provides an intelligent tunnel segment crane, comprising:

[0040] Curing pool 1, with a built-in circulating cooling water system and segment coordinate identification tags, is used to store and preserve prefabricated segments, and a mobile component 2 is provided on its top;

[0041] The binocular vision system 5 is installed inside the gantry system 3 and is used to scan the position of the pipe segments in the curing tank 1 and generate three-dimensional coordinates. The binocular vision system 5 does not rely solely on hardware positioning, but instead combines a multimodal image processing method based on binocular image input, including: image enhancement and illumination normalization algorithms; abnormal occlusion recognition and reconstruction algorithms; and target posture dynamic tracking achieved by the CNN-BiLSTM structure.

[0042] Modular telescopic boom 401, with a telescopic travel of 0-15m, and an integrated vacuum suction cup and mechanical claw composite grasping mechanism 402 at the end;

[0043] The six-dimensional force sensor 12 is installed in the rigid flange connection between the modular telescopic boom (401) and the composite gripping mechanism (402). A four-bolt flange mounting structure is used, with high-strength fastening bolts ensuring connection stability and measurement path integrity. To prevent stress interference, damping pads are provided around the force sensor to absorb vibration or impact in non-working directions. Its structural position is located at the force transmission node closest to the target segment in the lifting path, where it can directly sense changes in gripping torque, sway, lateral force, etc. In industrial robots and lifting machinery, the six-dimensional sensor layout in front of the end effector is a standard arrangement (refer to the UR5 robot arm, ABB boom, etc.).

[0044] The six-dimensional force sensor 12 collects force information in six dimensions, including three-axis linear force (Fx, Fy, Fz) and three-axis torque (Mx, My, Mz); the sensing axis is strictly aligned with the direction of the boom end to ensure that all load changes during the grasping process pass through the sensor sensing surface; the system uses the ROS algorithm embedded library to analyze the six-dimensional data in real time and determine whether there is a risk of overload, unbalanced load or collision.

[0045] The central controller 301 has a built-in industrial PLC and ROS algorithm module, receives data from the binocular vision system 5 and the six-dimensional force sensor 12, and controls the hoisting path planning and execution.

[0046] Please see the attached Figure 1 -Attached Figure 2 The mobile component 2 includes a carrying platform 202, and two mobile bases 201 are provided on both sides of the bottom of the carrying platform 202. The mobile base 201 is slidably connected to the top of the side wall of the curing pool 1. Protective fences 203 are installed all around the top of the carrying platform 202. The door machine system 3 includes a central controller 301, and mobile support legs 302 are provided on both sides of the bottom of the central controller 301. Mobile inner rails 303 are opened on both sides of the interior of the carrying platform 202, and the bottom of the mobile support leg 302 is slidably connected to the inside of the mobile inner rail 303.

[0047] Please see the attached Figure 2 -Attached Figure 3 The modular telescopic boom 401 is driven by a high-precision ball screw, with a telescopic positioning accuracy of ±1mm. The end of the boom is detachably connected to a foldable support frame. When the foldable support frame is unfolded, it contacts the tunnel side wall to form a triangular stable structure. The vacuum suction cup and mechanical claw composite grasping mechanism 402 includes:

[0048] Vacuum suction cup group 4021, arranged in the center area of ​​the segment, with a suction force of ≥5kN;

[0049] Adaptive mechanical grippers 4022 are symmetrically distributed on the edge of the segment, with a clamping angle adjustable by ±15°, and the clamping force dynamically matches the segment weight;

[0050] The anti-sway system uses the gyroscope feedback on the top of the modular telescopic boom 401 to control the servo motor to compensate for the displacement of the steel cable, so that the swing amplitude of the pipe segment is ≤3mm.

[0051] Please see the attached Figure 4 -Attached Figure 5 ,Multimodal safety monitoring system, the system includes:

[0052] Wind speed sensor 7, installed on the top of central controller 301, when wind speed>10m / s, lifting operation is prohibited;

[0053] The two mobile trolleys 8 are equipped with weight sensors 9 on one side of their tops to detect the weight they bear; the other side of the tops of the two mobile trolleys 8 are equipped with height sensors 10 to monitor the height of the crane 4 in real time; the weight sensor 9 adopts a suspended sensor structure (such as an S-type weighing sensor) to form a rigid connection with the main structure of the spreader; the force transmission path is from the spreader → boom → load-bearing node on the upper surface of the trolley → sensor, and the middle part of the structure has been verified by finite element analysis to be rigid enough to meet the accuracy requirements of load transfer; similar application structures are widely used in bridge cranes and dock hoisting equipment, and are mature solutions in this field; the mobile trolley 8 has a mobile adjustment function, which supports automatic positioning between multiple groups of pipe segments in the curing pool; in conjunction with the meter wheel 11 below, displacement measurement, synchronous recording of weight data and linkage with the hoisting path can be realized, which is a key component of the intelligent scheduling system;

[0054] The meter wheel 11 is used to measure the actual distance the crane moves on the track and, in conjunction with the control system, perform path planning error correction. The meter wheel 11, combined with an absolute encoder and a laser target, forms a fusion positioning system to ensure real-time and high-precision trajectory tracking.

[0055] The meter wheel is an important component of the crane movement path monitoring system. Its control logic is as follows:

[0056] As the crane moves, the meter wheel is in continuous contact with the track surface and rotates, recording the actual displacement;

[0057] The pulse signal of the meter wheel is converted into displacement data by the displacement encoder;

[0058] The central controller (PLC) receives the displacement data from the meter wheel in real time and compares it with the set path coordinates;

[0059] The meter wheel 11 is installed at the bottom center of the two mobile carts (8) and keeps in constant contact with the track surface. It is connected to the central controller through the same set of data acquisition modules as the height sensor 10 and the weight sensor 9 for multi-parameter coordinated control. An incremental rotary encoder or a magnetoelectric displacement sensor is provided and connected coaxially with the axis of the meter wheel. If there is a deviation between the actual moving path and the planned path, the system will send a position fine-tuning instruction to the mobile support leg through a feedback loop to achieve automatic deviation correction.

[0060] Please see the attached Figure 4 , a binocular vision system 5 is installed on the opposite side between the two mobile support legs 302, and an electric slide rail is provided inside the mobile support leg 302. The binocular vision system 5 is slidably connected to the inside of the electric slide rail. The binocular vision system 5 cooperates with the electric guide rail to adjust the viewing angle and supports scene acquisition at different depths; although optical devices such as liquid lenses are not used, the industrial-grade binocular module has a preset multi-level focal length and combines deep learning to achieve dynamic image calibration. It has been proven in engineering practice that it can adapt to different focal depths and lighting changes; an industrial computer 6 is installed on the opposite side between the two mobile support legs 302, and a video display is provided on the industrial computer 6. The industrial computer 6 has a built-in ROS algorithm module for receiving data from the binocular vision system 5 and the six-dimensional force sensor 12, generating a lifting path control instruction and outputting it to the industrial PLC controller.

[0061] In the actual deployment of the equipment, the baseline distance of the two binocular vision cameras of the binocular vision system 5 is an adjustable structure, which is adjusted to the target distance (generally set to 0.3m~1m) through the slide rail structure before startup, and then image acquisition is performed; the two mobile support legs 302 do not fix the binocular vision cameras on two completely independent structures, but the dual-camera combination module is supported by the central stable platform to ensure that the structural baseline length is within the effective range.

[0062] Please see the attached Figure 4 An absolute encoder and an anti-collision ranging sensor are installed at the bottom of the mobile support leg 302. Laser reflection targets are set every 1m on both sides of the track. The central controller 301 integrates the encoder pulse signal and the laser ranging data to achieve a door machine positioning error of ≤±2mm. The anti-collision ranging sensor communicates with the central controller 301. When it detects that the obstacle distance is less than the preset value, the three-level deceleration strategy is triggered.

[0063] Working principle: The central controller 301 scans the pipe segments in the curing tank 1 through the binocular vision system 5, obtains the position data of the pipe segments, and generates three-dimensional coordinates. The central controller 301 receives and processes data from the binocular vision system 5 and the six-dimensional force sensor 12, and calculates the hoisting path control instructions. Subsequently, these control instructions are transmitted to the industrial PLC controller to execute the hoisting action. The mobile component 2 slides on the top of the side wall of the curing tank 1 through the two mobile bases 201 on the supporting platform 202 to adjust the position of the crane 4. The mobile support legs 302 slide according to the electric slide rails in the track to ensure the stable movement of the crane 4 and cooperate with the instructions of the central controller 301 for precise positioning.

[0064] The modular telescopic boom 401 extends and retracts according to the instructions of the central controller 301. The vacuum suction cup and mechanical claw composite grasping mechanism 402 at the end grasps the pipe segment through adsorption and clamping and prepares for lifting. The electric slide is connected to the binocular vision system 5 to ensure that the vision system can adjust its position according to work needs and adapt to the lifting requirements of different pipe segments. The anti-sway system adjusts the servo motor through the feedback information of the gyroscope on the modular telescopic boom 401 to ensure that the pipe segment does not swing excessively during the lifting process. The mobile trolley 8 monitors the lifting weight through the weight sensor 9 and provides real-time feedback on the working height of the crane 4 through the height sensor 10, assisting the central controller 301 in dynamic adjustment.

[0065] Anti-collision ranging sensors communicate with the central controller 301 to detect obstacles in real time. If an obstacle is detected approaching, the system triggers a three-stage deceleration strategy. Laser reflective targets on both sides of the track work in conjunction with the ranging sensors to provide precise displacement data, ensuring that the door operator's positioning error is controlled within ±2mm.

[0066] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An intelligent tunnel segment crane, characterized in that: include: A curing pool (1) having a built-in circulating cooling water system and segment coordinate identification tags for storing and preserving prefabricated segments, with a moving assembly (2) provided on the top; A binocular vision system (5) is installed inside the gantry system (3) and is used to scan the position of the pipe segments in the curing tank (1) and generate three-dimensional coordinates; A modular telescopic boom (401) with a telescopic travel of 0-15m and an integrated vacuum suction cup and mechanical claw composite grasping mechanism (402) at the end; A six-dimensional force sensor (12) is provided at the connection between the modular telescopic boom (401) and the vacuum suction cup and mechanical claw composite grasping mechanism (402), and is used for real-time detection of load torque and collision signals; The central controller (301) has a built-in industrial PLC and ROS algorithm module, receives data from the binocular vision system (5) and the six-dimensional force sensor (12), and controls the planning and execution of the lifting path.

2. The intelligent tunnel segment crane according to claim 1, characterized in that: The mobile assembly (2) includes a carrying platform (202), and two mobile bases (201) are provided on both sides of the bottom of the carrying platform (202), the mobile bases (201) are slidably connected to the top of the side wall of the curing pool (1), and protective fences (203) are installed around the top of the carrying platform (202).

3. The intelligent tunnel segment crane according to claim 2, characterized in that: The door machine system (3) includes a central controller (301), and movable support legs (302) are provided on both sides of the bottom of the central controller (301), and movable inner rails (303) are provided on both sides of the interior of the carrying platform (202), and the bottom of the movable support legs (302) is slidably connected to the inside of the movable inner rails (303).

4. The intelligent tunnel segment crane according to claim 3, characterized in that: The modular telescopic boom (401) is driven by a high-precision ball screw, with a telescopic positioning accuracy of ±1 mm, and the end is detachably connected to a foldable support frame, which contacts the tunnel side wall to form a triangular stable structure after being unfolded.

5. The intelligent tunnel segment crane according to claim 4, characterized in that: The vacuum suction cup and mechanical claw composite grasping mechanism (402) comprises: The vacuum suction cup group (4021) is arranged in the center area of ​​the pipe segment, and the suction force is ≥5kN; Adaptive mechanical claws (4022) are symmetrically distributed on the edge of the segment, with a clamping angle adjustable by ±15° and a clamping force dynamically matching the segment weight; The anti-sway system controls the servo motor to compensate for the displacement of the steel cable through the feedback of the gyroscope on the top of the boom (401), so that the swing amplitude of the pipe segment is ≤3mm.

6. The intelligent tunnel segment crane according to claim 3 further comprises a multi-modal safety monitoring system, characterized in that: The system comprises: A wind speed sensor (7) is installed on the top of the central controller (301). When the wind speed is greater than 10 m / s, lifting operations are prohibited. A mobile trolley (8), wherein a weight sensor (9) is installed on one side of the top of each of the two mobile trolleys (8) for detecting the weight borne; and a height sensor (10) is installed on the other side of the top of each of the two mobile trolleys (8) for real-time monitoring of the height of the crane (4); The meter wheel (11) is used to calculate the displacement of the mobile vehicle (8).

7. The intelligent tunnel segment crane according to claim 3, characterized in that: A binocular vision system (5) is installed on one side opposite to the other of the two movable support legs (302), and an electric slide rail is provided inside the movable support legs (302), and the binocular vision system (5) is slidably connected inside the electric slide rail.

8. The intelligent tunnel segment crane according to claim 7, characterized in that: An industrial computer (6) is installed on each of the two opposite sides of the mobile support legs (302), and a video display is provided on the industrial computer (6). The industrial computer (6) has a built-in ROS algorithm module for receiving data from a binocular vision system (5) and a six-dimensional force sensor (12), generating a hoisting path control instruction, and outputting the instruction to an industrial PLC controller.

9. The intelligent tunnel segment crane according to claim 8, characterized in that: An absolute encoder and an anti-collision distance measurement sensor are installed at the bottom of the movable support leg (302), and laser reflection targets are set every 1m on both sides of the track. The central controller (301) achieves a door machine positioning error of ≤±2mm by fusing the encoder pulse signal and the laser distance measurement data.

10. The intelligent tunnel segment crane according to claim 9, characterized in that: The anti-collision ranging sensor communicates with the central controller and triggers a three-level deceleration strategy when it detects that the obstacle distance is less than a predetermined value.

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