Automatic load balancing system of tower hoisting machinery and control method

Abstract

The invention discloses an automatic load balancing system of tower hoisting machinery and a control method. The system comprises a sensor, an encoder, a counterweight moving device and a main control unit, the gravity sensor and the encoder are positioned on the lifting hook; the torque sensor and the counterweight moving device are mounted on the large arm; the counterweight moving device comprises a sliding rail and a plurality of counterweight blocks each provided with a counterweight body, a pulley and a sub-control unit, and the sub-control units are responsible for receiving a master control instruction and feeding back a state. The main control unit calculates the total torque of the load, the number of required counterweights and the reverse torque according to the weight of the hoisted object, the horizontal distance and the initial torque, and the load is balanced by dynamically adjusting the positions of the counterweights. In the operation process, the distance between the adjacent balancing weights is monitored and adjusted in real time so as to avoid collision, and by implementing the method, the change of the weight and position of a hoisted object can be sensed and responded in real time, so that the positions of the balancing weights are dynamically adjusted, the balance of load moments on the two sides of a large arm of the tower crane is ensured, and the safety and efficiency of operation are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to tower cranes, more particularly to an automatic load balancing system and control method for tower cranes. BACKGROUND

[0002] Traditional tower cranes usually balance the load at the end of the hoisted object by placing fixed counterweights, motors and other devices on the other side of the jib. The design of such fixed counterweights aims to offset the moment of the hoisted object end, ensuring the stability of the tower crane during operation.

[0003] However, since these counterweights are fixed, they cannot be dynamically adjusted according to the actual weight and position of the hoisted object. When the weight of the hoisted object or its position relative to the tower changes, the existing fixed counterweights often cannot match the new load conditions, resulting in an imbalance of the moments on both sides of the tower crane. Especially in the case of a particularly heavy hoisted object or a long distance from the tower, the unbalanced moment will cause the tower crane bottom to bear more lateral force, increasing the risk of equipment damage and possibly affecting the safety of the entire structure.

[0004] Therefore, it is necessary to design a new system that can sense and respond to changes in the weight and position of the hoisted object in real time, dynamically adjust the position of the counterweight blocks, ensure the balance of the load moments on both sides of the tower crane jib, and improve the safety and efficiency of the operation. SUMMARY

[0005] The purpose of the present application is to overcome the defects of the prior art and provide an automatic load balancing system and control method for tower cranes.

[0006] To achieve the above-mentioned purpose, the present application adopts the following technical solution: an automatic load balancing system for tower cranes, comprising: a sensor, an encoder, a counterweight moving device, and a main control unit, the sensor comprising a gravity sensor and a moment sensor, the gravity sensor and the encoder being installed on the hook, the counterweight moving device and the moment sensor being assembled on the jib, the counterweight moving device comprising a sliding rail and a plurality of counterweight blocks moving on the sliding rail, each counterweight block comprising a counterweight body, a pulley, and a sub-control unit, the sub-control unit being connected to the main control unit for receiving instructions from the main control unit to control the movement of the corresponding counterweight block and feedback the moving distance of the pulley and the position of the counterweight block; The main control unit is used to calculate the total load moment at the end of the hoisted object and the number of required counterweight blocks and the reverse moment according to the weight of the hoisted object, the horizontal distance from the hoisted object to the tower, and the initial moment of the counterweight moving device. The sub-control unit dynamically adjusts the moving distance of the corresponding counterweight block on the sliding rail to generate the corresponding reverse moment, achieving the balance of the load at the end of the hoisted object of the tower crane. During the movement of the counterweight, the distance between adjacent counterweights is monitored in real time to adjust the movement of the counterweight and avoid collision between adjacent counterweights.

[0007] Further technical solutions are that the initial torque of the counterweight movement device includes a counterweight end fixed torque and an initial provided torque. The main control unit calculates the maximum torque that needs to be additionally provided and the distance that a single counterweight needs to move according to the load torque of the hoisting object end, the counterweight end fixed torque and the torque provided by the counterweight slide rail, and if the moving distance of a single counterweight is insufficient to meet the requirements, the number of counterweights that need to be moved and the exact moving distance of the last counterweight are calculated to compensate, and instructions are sent to command each counterweight to move to the corresponding target position on the slide rail to generate a corresponding reverse torque, so as to ensure the load balance between the hoisting object end and the counterweight end.

[0008] Further technical solutions are that the instructions contain a start time parameter, which is set as a delay interval after the current time to ensure that all the counterweights can receive the instructions and perform displacement operations at the same time point within a specified time.

[0009] Further technical solutions are that the main control unit periodically performs discrete sampling of the load torque and allows the counterweights to dynamically change the corresponding target positions according to the latest load torque information during the movement.

[0010] Further technical solutions are that the counterweight further includes a laser sensor and a drive motor, the laser sensor is used to prevent collision between the counterweights, and the drive motor is used to move the corresponding counterweight according to the position information provided by the encoder. When the sub-control unit receives the instructions sent by the main control unit, the displacement requirements in the instructions are converted into encoder positions, and the drive motor is controlled to move the counterweight, and during the movement, the distance between adjacent counterweights is monitored by the laser sensor to control the working state of the drive motor to avoid collision between adjacent counterweights and dynamically adjust the target position.

[0011] The application also provides a control method of the automatic load balancing system of the tower crane, which comprises the following steps: The main control unit calculates the total load torque of the hoisting object end, the number of counterweights required and the reverse torque according to the weight of the hoisting object collected by the gravity sensor, the horizontal distance from the hoisting object to the tower body and the initial torque of the counterweight movement device to form instructions. The main control unit sends instructions to the sub-control units to control the movement of the corresponding counterweights by the sub-control units, dynamically adjusts the movement distance of the corresponding counterweights on the slide rail to generate corresponding counter-torque, and feeds back the movement distance of the pulley and the position of the counterweight.

[0012] Further technical solutions are that the main control unit calculates the total load torque at the object end and the number and counter-torque of the required counterweights according to the object weight collected by the gravity sensor, the horizontal distance from the object to the tower body, and the initial torque of the counterweight movement device, to form instructions, including: The object weight and the horizontal distance from the object to the tower body are obtained by sensors and encoders, and the total load torque at the object end is calculated; The object weight and the horizontal distance from the object to the tower body are transmitted to the main control unit; The main control unit calculates the maximum torque of the required counterweight according to the maximum design parameter; When additional counterweights are required, the number of individual and required counterweights and their specific movement distances are calculated based on the additional required counterweight torque to generate instructions; The main control unit sends instructions to the sub-control units to guide the movement of the counterweights along the slide rail by the sub-control units, and continuously monitors and dynamically adjusts the position of the counterweights as needed.

[0013] Further technical solutions are that the main control unit sends instructions to guide the movement of the counterweights along the slide rail, and continuously monitors and dynamically adjusts the position of the counterweights, including: During the movement of the counterweights, the main control unit periodically performs discrete sampling of the load torque, and allows the counterweights to dynamically change the target position during movement according to the latest load torque information.

[0014] Further technical solutions are that the sampling interval of the discrete sampling is set according to the trolley speed.

[0015] Further technical solutions are that the main control unit sends instructions to the sub-control units to guide the movement of the counterweights along the slide rail by the sub-control units, and continuously monitors and dynamically adjusts the position of the counterweights, including: During the movement of the counterweights, the distance between the counterweights is monitored in real time by means of a laser sensor to prevent collision, and the movement path is dynamically adjusted to adapt to load changes.

[0016] The beneficial effects of the present application compared with the prior art are: the present application realizes real-time sensing of the weight and position change of the hoisted object by integrating the gravity sensor and the torque sensor in the hook and assembling the counterweight moving device and the torque sensor in the jib; the system comprises a slide rail and a plurality of counterweight blocks movable on the slide rail, each counterweight block is equipped with a sub-control unit and can receive the instruction of the main control unit to move accurately and feed back the position information; the main control unit calculates the total load torque and the required counter torque according to the weight of the hoisted object, the horizontal distance to the tower body and the initial torque of the counterweight moving device, dynamically adjusts the position of the counterweight block to generate the corresponding counter torque, so as to realize load balancing. During the movement of the counterweight block, the system can also monitor the distance between adjacent counterweight blocks in real time to prevent collision and ensure the balance of the load torque on both sides of the jib of the tower crane, thereby improving the safety and efficiency of the operation; this mechanism enables the tower crane to quickly respond to the change of the hoisted object during operation, optimizes the distribution of the counterweight blocks and ensures the safe and stable operation of the equipment.

[0017] The present application will be further described below in conjunction with the drawings and specific embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0019] Figure 1 A schematic block diagram of the automatic load balancing system of the tower crane provided by the embodiment of the present application is shown in the figure. Figure 2 An installation schematic of the counterweight block and the slide rail provided by the embodiment of the present application is shown in the figure. Figure 1 Figure 3 An installation schematic of the counterweight block and the slide rail provided by the embodiment of the present application is shown in the figure. Figure 2 Figure 4 A connection schematic of the laser sensor and the driving motor provided by the embodiment of the present application is shown in the figure. Figure 5 A schematic diagram of torque calculation provided by the embodiment of the present application is shown in the figure. Figure 6 A flowchart of the control method of the automatic load balancing system of the tower crane provided by the embodiment of the present application is shown in the figure. Figure 7 A sub-flowchart of the control method of the automatic load balancing system of the tower crane provided by the embodiment of the present application is shown in the figure. DETAILED DESCRIPTION

[0020] ​​With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described, obviously, the described embodiments are a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0021] It should be understood that the terms "comprising" and "including" as used in the specification and the appended claims indicate the presence of the described features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0022] It should also be understood that the terms used in the present application specification are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the present application specification and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0023] It should be further understood that the term "and / or" as used in the present application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations thereof.

[0024] Please refer to Figures 1 to 3 The automatic load balancing system of the tower crane provided by the embodiment comprises a sensor 10, an encoder 20, a counterweight moving device, and a main control unit 30. The sensor 10 comprises a gravity sensor 10 and a torque sensor 10, the gravity sensor 10 and the encoder 20 are installed on a hook, the counterweight moving device and the torque sensor 10 are assembled on a large arm 70, the counterweight moving device comprises a slide rail 60 and a plurality of counterweight blocks 50 moving on the slide rail 60, each counterweight block 50 comprises a counterweight body, a pulley, and a sub-control unit, the sub-control unit is connected with the main control unit 30, used for receiving instructions of the main control unit 30 to control the movement of the corresponding counterweight block 50, and feeding back the moving distance of the pulley and the position of the counterweight block 50. The main control unit 30 is used for calculating the total load torque at the end of the hoisted object, the number of required counterweight blocks 50, and the reverse torque according to the weight of the hoisted object, the horizontal distance from the hoisted object to the tower body, and the initial torque of the counterweight moving device, the sub-control unit dynamically adjusts the moving distance of the corresponding counterweight block 50 on the slide rail 60 to generate the corresponding reverse torque, so as to balance the load at the end of the hoisted object of the tower crane. In the process of moving the counterweight block 50, the distance between adjacent counterweight blocks 50 is monitored in real time to adjust the movement of the counterweight block 50, so as to avoid collision between adjacent counterweight blocks 50.

[0025] In this embodiment, the system aims to balance the moment of force on both ends of the tower crane's jib 70 by monitoring the weight and position of the hoisted object in real time and dynamically adjusting the position of the counterweights 50 according to this information, thereby reducing the pressure on the tower crane's support structure and improving the safety and stability of the operation.

[0026] Among them, the sensor 10 includes a gravity sensor 10 and an encoder 20, which are installed on the hook and used to obtain the weight of the hoisted object and the horizontal distance from the hoisted object to the tower body.

[0027] The counterweight moving device is composed of a sliding rail 60 and multiple counterweights 50 that can move on the sliding rail 60. Each counterweight 50 contains a counterweight body, a pulley, and a sub-control unit.

[0028] The main control unit 30 is responsible for processing data from the sensor 10, calculating the required number of counterweights 50 and their positions, and sending instructions to each sub-control unit.

[0029] The sub-control unit is connected to the main control unit 30, receives instructions and controls the movement of the corresponding counterweight 50, while feeding back the position information of the counterweight 50 to the main control unit 30.

[0030] The system of this embodiment obtains the weight of the hoisted object and the horizontal distance information from the hoisted object to the tower body through the gravity sensor 10 and the encoder 20 respectively. These information is transmitted to the main control unit 30 for further processing and analysis. The main control unit 30 calculates the moment of force change of the current hoisted object according to the obtained weight and distance information. According to the calculated total load moment of the hoisted object end, the main control unit 30 determines the number of counterweights 50 that need to be adjusted and their new positions to generate the corresponding counter moment, achieving moment balance. The sub-control unit accurately controls the movement of each counterweight 50 according to the instructions received from the main control unit 30. During the movement, the distance between adjacent counterweights 50 is monitored in real time by the laser sensor 80 to avoid collision.

[0031] During the entire adjustment process, the sub-control unit continuously feeds back the position information of the counterweight 50 to the main control unit 30, so that the main control unit 30 can make more accurate adjustments according to the latest load situation.

[0032] Thus, the system of this embodiment ensures that the counterweights 50 can quickly respond to changes in load moment through discrete sampling and dynamic control technology. The use of laser radar prevents collision between counterweights 50, enhancing the safety and robustness of the system. The system can flexibly adjust the number and position of the counterweights 50 according to different load requirements, adapting to various working conditions.

[0033] This automatic load balancing system for tower cranes greatly improves the safety and efficiency of tower crane operation and reduces the risk of equipment damage caused by imbalance.

[0034] In one embodiment, the initial torque of the counterweight moving device described above includes the counterweight end fixing torque and the initial supply torque; The main control unit 30 calculates the maximum additional torque required and the distance that a single counterweight 50 should move, based on the load torque at the suspended end, the fixing torque at the counterweight end, and the initial torque provided by the counterweight slide rail 60 collected by the torque sensor 10. If the moving distance of a single counterweight 50 is insufficient to meet the requirements, the main control unit 30 calculates the number of counterweights 50 that need to be moved and the exact moving distance of the last counterweight 50 for compensation, and sends a command to direct each counterweight 50 to move to the corresponding target position on the slide rail 60 to generate the corresponding reverse torque, ensuring the load balance between the suspended end and the counterweight end.

[0035] In this embodiment, the initial torque of the counterweight moving device in the automatic load balancing system of tower crane machinery consists of two parts: the counterweight end fixing torque. The initial torque provided by the counterweight slide rail 60 The system ensures load balance between the load end and the counterweight end by monitoring and adjusting the position of the counterweight 50 in real time.

[0036] The main control unit 30 first obtains the following information from the sensor 10: Weight of the suspended object (M); The horizontal distance L from the suspended load to the tower body; Based on this information, the load moment exerted by the hoisted loads relative to the tower body is The moment of the boom 70 relative to the tower body at the end of the hoisting load remains constant, denoted as... Then the total load torque at the end of the suspended object is ,in This refers to the fixing torque of the boom 70 relative to the tower body at the end of the hoisting load. Then, the main control unit 30 determines the load torque at the hoisting load end and the fixing torque at the counterweight end based on these parameters. and the initial torque provided by the counterweight slide rail 60 Calculate the maximum additional torque required. The maximum lifting weight of the tower crane is designed to be... The tower crane is designed to lift a maximum distance of [distance not specified]. The fixing torque of the 70mm boom at the lifting end is The fixing torque of the counterweight end boom 70 is .

[0037] Next, after the main control unit 30 obtains the weight of the load and the horizontal distance of the trolley, it then... The counterweight needs to be provided additionally. The main control unit 30 determines the distance that the individual counterweight 50 needs to move according to the calculated maximum torque , where m is the mass of the individual counterweight 50, and g is the acceleration of gravity. If the length of the slide rail 60 is limited and insufficient for the individual counterweight 50 to complete the required movement, the number of counterweights 50 that need to be moved is calculated , rounded off, and the exact movement distance of the last counterweight 50 is calculated .

[0038] Once the calculation is complete, the main control unit 30 sends instructions to each sub-control unit to command the counterweights 50 under their respective control to move to the corresponding target position on the slide rail 60 to generate the corresponding counter-torque. The specific steps are as follows: The main control unit 30 starts to allocate the first counterweight 50 and moves it to the designated position.

[0039] If the counterweight 50 has reached the designated position, proceed to the next step; if not, continue to adjust until it is in place.

[0040] If all counterweights 50 have been allocated and are in place, the entire configuration action is complete and waits for the next operation; if there are counterweights 50 that have not been allocated or are not in place, return to the previous step to allocate the next counterweight 50 until all counterweights 50 are allocated and in place.

[0041] Throughout the process, the sub-control units continuously monitor the positions of the counterweights 50 and prevent collisions between the counterweights 50 through laser radar. At the same time, the sub-control units also dynamically receive and modify the movement position information to adapt to the continuous changes in the load torque, thereby achieving precise control and management of the displacement of the device.

[0042] Through this precise calculation and dynamic adjustment mechanism, the tower crane automatic load balancing system can effectively balance the torque between the load end and the counterweight end, improving the safety and stability of the tower crane operation. This method not only improves work efficiency, but also significantly reduces the risk of equipment damage caused by imbalance.

[0043] In an embodiment, the above-mentioned instructions contain a start time parameter, which is set as a delay interval after the current time to ensure that all counterweights 50 can receive the instructions and perform the displacement operation at the same time point within the specified time.

[0044] Specifically, the main control unit 30 of the tower crane automatic load balancing system includes a start time parameter when sending movement instructions to each counterweight 50. This parameter is designed as a delay interval after the current time, aiming to ensure that all sub-control units (i.e., the independent control systems of each counterweight 50) can start displacement operations at the same time point. The following is a detailed explanation of this mechanism: 1. Instruction generation and transmission When the main control unit 30 calculates the number of counterweights 50 to be adjusted and their positions based on the moment information of the load end and the counterweight end, it will generate corresponding movement instructions. These instructions not only include the target position of each counterweight 50, but also include a key time parameter - start time.

[0045] The start time parameter is set to the current time plus a specific delay interval. The length of this delay interval is determined based on the following factors: Ensure the longest time required for all subsystems to receive instructions.

[0046] Consider the instability or delay of wireless communication, to ensure that even in poor network conditions, there is enough time for all counterweights 50 to receive instructions.

[0047] Consider the synchronization error and safety margin in practical applications to ensure that all counterweights 50 start moving almost simultaneously.

[0048] By setting a unified start time, it can avoid the situation that some counterweights 50 move ahead and others lag behind due to differences in network transmission speed. This synchronization is crucial for maintaining the stability and safety of the entire system, as it ensures that counterweights 50 can respond to moment changes in coordination, effectively reducing the pressure on the tower crane support structure.

[0049] Once the calculation is complete, the main control unit 30 immediately issues movement instructions to each sub-control unit, including target position and start time. After receiving the instructions, each sub-control unit enters a waiting state until the set start time arrives. At the preset start time, all counterweights 50 almost simultaneously start moving in the specified direction and distance, achieving precise load adjustment.

[0050] It is worth noting that in some cases, if new moment changes are detected during the movement of the counterweights 50 (for example, the position or weight of the load changes), the main control unit 30 can recalculate and update the movement instructions based on the latest data, including new target positions and start times, so that the system can dynamically adapt to changes and maintain the best load balancing state.

[0051] In summary, by introducing the instruction mechanism with start time parameters, the tower crane automatic load balancing system can more accurately and efficiently realize the coordinated movement of the counterweight blocks 50, greatly improving the safety and efficiency of the operation. This method effectively solves the synchronization problem caused by wireless communication delay or instability, ensuring the reliable operation of the system.

[0052] In an embodiment, the main control unit 30 described above periodically performs discrete sampling of the load torque and allows the counterweight blocks 50 to dynamically change their target positions during movement according to the latest load torque information.

[0053] Specifically, the main control unit 30 is designed to periodically perform discrete sampling of the load torque and allows the counterweight blocks 50 to dynamically change their target positions during movement according to the latest load torque information.

[0054] The main control unit 30 samples the current load torque at a set time interval (e.g. every second or more frequently). The choice of this time interval needs to balance the real-time nature of data updates and the consumption of computing resources. Each sampling includes but is not limited to factors such as the weight of the suspended object, which together determine the current load torque state.

[0055] Once the main control unit 30 obtains new load torque data, it will immediately assess whether it needs to adjust the position of the counterweight blocks 50 to maintain the balance of the system. This dynamic adjustment mechanism has the following three characteristics: Based on the latest torque information, the main control unit 30 quickly calculates the required adjustment amount of the counterweight blocks 50 position. This may involve the repositioning of a single or multiple counterweight blocks 50.

[0056] If it is determined that adjustment is needed, the main control unit 30 will immediately issue updated movement instructions to the relevant sub-control units, which contain the new target position and the corresponding start time parameter.

[0057] To ensure the safety and stability of the operation, when changing the target position of the counterweight blocks 50, the main control unit 30 may adopt a gradual adjustment strategy, i.e. gradually guiding the counterweight blocks 50 to approach the new target position, rather than directly making large changes.

[0058] Even in the case of rapid changes in load conditions, the system can always be in the optimal balanced state, reducing the risk of sudden imbalance. It can adapt to complex and variable working environments, such as sudden weather conditions encountered during high-altitude operations, and the system can respond in time. Avoid unnecessary movement and energy waste, improve the efficiency and economy of the entire system.

[0059] In an embodiment, please refer to Figure 4The counterweight 50 also includes a laser sensor 80 and a drive motor 90. The laser sensor 80 is used to prevent collisions between counterweights 50. The drive motor 90 is used to move the associated counterweight 50 according to the position information provided by the encoder 20. When the sub-control unit receives the instruction sent by the main control unit 30, it converts the displacement requirement in the instruction into an encoder 20 position and controls the drive motor 90 to move the counterweight 50. During the movement, the laser sensor 80 monitors the distance between adjacent counterweights 50 to control the working state of the drive motor 90 to avoid collisions between adjacent counterweights 50 and dynamically adjust the target position.

[0060] In this embodiment, the design and operation mechanism of the counterweight 50 are further refined and optimized to ensure the safety and stability of the tower crane during hoisting operations. Specifically, each counterweight 50 not only contains a traditional weight component, but also integrates advanced elements such as laser sensors 80 and drive motors 90. These elements work together to ensure that the counterweight 50 can flexibly adjust its position according to the real-time changing load conditions, while avoiding collisions with other counterweights 50.

[0061] Each counterweight 50 is equipped with at least one pair of laser sensors 80 (one in front and one in back) to monitor the distance between adjacent counterweights 50 in real time. Once the detected distance is less than the preset safety threshold, the system will immediately take measures to suspend or slow down the movement of the current counterweight 50, thereby avoiding potential collision risks.

[0062] The laser sensors 80 are usually installed at the front and rear ends of the counterweight 50, so that the distance between the front and rear counterweights 50 can be accurately measured.

[0063] The drive motor 90 is a key component that drives the counterweight 50 to move along the slide rail 60 based on the position information provided by the encoder 20. It can accurately move the counterweight 50 to the specified position according to the instructions sent by the main control unit 30 to balance the moment of the hoisted object.

[0064] The action of the drive motor 90 is directly controlled by the sub-control unit, which is responsible for analyzing the displacement requirement received from the main control unit 30 and converting it into specific encoder 20 position information to guide the drive motor 90 to perform the corresponding movement operation.

[0065] When the sub-control unit receives the instruction from the main control unit 30, the entire operation process is as follows: The sub-control unit first analyzes the received instruction and extracts the displacement requirement parameter, and converts it into encoder 20 position information that the drive motor 90 can recognize.

[0066] If the target position needs to be updated due to changes in the load moment during the movement of the counterweight 50, the sub-control unit can receive and process new instructions in real time, immediately adjusting the target position of the counterweight 50 to ensure that the optimal balance state is always maintained.

[0067] Through the integrated laser sensor 80, the sub-control unit continuously monitors the distance between adjacent counterweights 50. Once any situation that may cause a collision is found, the system will automatically adjust the working state of the drive motor 90, such as temporarily stopping or slowing down, until the safe distance is restored.

[0068] After confirming that the forward distance is sufficient and there is no risk of collision, the sub-control unit sets the target position of the encoder 20 and sends a start signal to the drive motor 90. Throughout the movement, the system continuously checks whether the predetermined position has been reached to ensure that the final parking accuracy meets the requirements.

[0069] The entire process is a continuous cycle, with the sub-control unit continuously receiving new instructions, adjusting strategies, and performing actions until all counterweights 50 complete position adjustment according to the latest load conditions.

[0070] This design not only improves the adaptability of the tower crane in complex working environments, but also greatly enhances the reliability and safety of the system, allowing it to maintain good balance performance even in the face of rapidly changing load conditions. In addition, by precisely controlling the movement of the counterweight 50, unnecessary energy consumption is reduced, helping to improve overall work efficiency.

[0071] For the automatic load balancing system of the tower crane described above, the total load at the hoisted object end is composed of two parts: the weight of the hoisted object itself and the part of the jib 70 that protrudes from the tower at the hoisted object end. Assuming the hoisted object weight is M and the horizontal distance from the hoisted object to the tower is L, the load moment of the hoisted object relative to the tower is where g is the acceleration due to gravity. In addition, the jib 70 at the hoisted object end has a fixed moment relative to the tower Therefore, the total load moment at the hoisted object end can be expressed as: Here, the weight of the hoisted object is obtained through the gravity sensor 10 on the hook, and the force arm (i.e., the horizontal distance from the hoisted object to the tower) is obtained through the encoder 20 data conversion. These two data are transmitted to the control center (intelligent computing unit) through a wireless network to facilitate the calculation of the counterweight adjustment required.

[0072] ​The number of counterweights 50 on the slide rails 60 is determined according to the maximum load of the tower crane. These counterweights 50 can be moved on the slide rails 60 according to the instructions of the main control unit 30 to achieve the desired counterweight balance. Specifically, the sub-control unit can receive messages from the main control unit 30, know the distance traveled by the pulley, and can feedback the position of the counterweight 50 to the control center if necessary.

[0073] Assuming that the maximum weight that can be lifted by the tower crane is , the maximum lifting distance is , the fixed moment of the load end jib 70 is , and the fixed moment of the counterweight end jib 70 is , then the maximum moment that the counterweight structure needs to provide is , which can be expressed as: ; If it is assumed that there are two pairs of slide rails 60 on the jib 70, each pair of slide rails 60 has n counterweights 50, each counterweight 50 weighs m, and the length of the slide rail 60 is h, then the maximum counterweight moment that can be provided additionally is , which is: ; and when all counterweights 50 are not moved, the counterweight moment they can provide is set to , so the total counterweight moment is: ; this can quantitatively determine the relationship between the length of the slide rail 60, the weight and number of counterweights 50.

[0074] As shown in Figure 5 , when the main control unit 30 obtains the weight of the load and the horizontal distance of the trolley, it calculates the additional counterweight required according to the formula . Then, according to this result, the distance that a single counterweight 50 needs to move is calculated. Since the length of the slide rail 60 is limited, if a single counterweight 50 cannot meet the required moving distance, the remaining part will be supplemented by other counterweights 50. In this way, the number of counterweights 50 that need to be moved is: (rounded); finally, the distance x that the last counterweight 50 needs to move is: . Once the calculation is complete, the control center assigns the moving distance to the corresponding counterweight 50, so that they move to the designated position on the slide rail 60 to achieve load balance with the load end.

[0075] The system obtains the weight information of the hoisted object through the gravity sensor 10 and the distance information from the tower body through the encoder 20; the gravity sensor 10 and the encoder 20 transmit the obtained weight and distance information to the control center; the control center calculates the moment change of the current hoisted object according to the received information; based on the above calculation, the control center determines the number of counterweights 50 to be allocated and their positions.

[0076] The first counterweight 50 is allocated and moved to the designated position; it is checked whether the counterweight 50 has reached the designated position; if not, it is continuously adjusted until it is in place.

[0077] It is confirmed that all counterweights 50 have been allocated and are in place; if not, the previous step is returned to allocate the next counterweight 50 until all counterweights 50 are allocated and in place.

[0078] The whole process realizes the precise control and management of the hoisted object counterweight by continuously circulating the above steps, ensuring the safety and stability of the hoisting operation.

[0079] In this embodiment, the main control unit 30 uniformly manages the entire load balancing system, while the sub-control unit is responsible for the independent control of each counterweight 50. The main control unit 30 uses an SOC chip as the core, reads the data transmitted by the sensor 10, and determines the number of counterweights 50 to be moved and the distance each counterweight 50 needs to move using a predetermined calculation formula. These control data are transmitted to each counterweight 50 through LoRa wireless transmission.

[0080] In order to deal with the time difference problem of wireless transmission, the main control unit 30 adopts a timed movement method. Each sub-control unit has a start time parameter when receiving the instruction, ensuring that all counterweights 50 can start moving at the same time.

[0081] Considering that the load moment is continuously changing in actual operation, the system adopts a discrete sampling strategy, collecting weight and position information every fixed time, ensuring enough buffer time to complete counterweight adjustment while retaining real-time performance. In addition, the system supports dynamic control, which can change the target position in real time even when the counterweight 50 is moving, adapting to changes in load moment. This design not only improves the flexibility and response speed of the system, but also enhances the overall stability and safety.

[0082] In this embodiment, the sub-control unit can ensure that the counterweight 50 can move accurately according to the instructions of the main control system, while avoiding collisions between the counterweights 50.

[0083] The laser sensor 80 is mainly used to detect the distance between adjacent counterweights 50 to prevent collisions during movement.

[0084] The driving motor 90 is responsible for driving the movement of the counterweight 50, and records the position information through the encoder 20 to ensure the accuracy of each movement.

[0085] Specifically, the displacement information is obtained through the laser sensor 80 and transmitted to the sub-control unit for processing. These information includes the current position of the counterweight 50 relative to other counterweights 50, and whether the position needs to be adjusted.

[0086] The sub-control unit determines whether the device has reached the preset forward distance according to the received displacement information. If the forward distance is sufficient, the next step is continued; otherwise, it is paused for further instructions.

[0087] When it is confirmed that the forward distance is sufficient, the sub-control unit converts the displacement information into the encoder 20 position of the driving motor 90 (the displacement information and the encoder 20 position are generally a fixed linear function relationship). This step ensures the accuracy of subsequent actions.

[0088] After the encoder 20 position is set, the sub-control unit sends an enable signal to the driving motor 90 to start the motor operation. At this time, the driving motor 90 drives the entire counterweight 50 to start moving.

[0089] During the movement of the counterweight 50, the sub-control unit will detect the front and rear distance between the counterweight 50 and other counterweights 50 in real time through the laser sensor 80. If the forward distance is less than the threshold value, the micro-control unit will pause the movement of the counterweight 50 until the forward distance is greater than the threshold value again.

[0090] At the same time, the sub-control unit dynamically receives and modifies the movement position information, dynamically determines the moving destination position of the counterweight 50, so as to adapt to the continuous change of the load torque.

[0091] After the driving motor 90 starts working, the system continues to monitor whether the device has reached the preset encoder 20 position. If the device has reached the specified position, it enters a waiting state, preparing for the next movement; if it has not reached, it continues to drive the motor 90 until the target position is reached.

[0092] In the whole process, the sub-control unit not only realizes the accurate control and management of the displacement of the device, but also enhances the flexibility and safety of the system in the following ways: Through the laser sensor 80, the distance between adjacent counterweights 50 is monitored in real time to ensure that no collision occurs during movement. Even if the counterweight 50 is moving, the target position can be changed in real time to adapt to the continuous change of the load torque.

[0093] Through the continuous circulation of the above steps, the sub-control unit can effectively respond to the instructions of the main control system, ensuring that the counterweight 50 moves accurately according to the predetermined plan, thereby realizing the safety and stability of the hoisting operation. This design not only improves the flexibility and response speed of the system, but also enhances the overall stability and safety.

[0094] The above-mentioned automatic load balancing system of tower crane realizes real-time sensing of the weight and position changes of the hoisted object by integrating the gravity sensor 10 and the torque sensor 10 on the hook, and assembling the counterweight moving device and the torque sensor 10 on the jib 70; the system includes a slide rail 60 and a plurality of counterweight blocks 50 that can move on the slide rail 60, each counterweight block 50 is equipped with a sub-control unit that can receive instructions from the main control unit 30 to move accurately and feedback its position information; the main control unit 30 calculates the total load torque and the required counter torque according to the weight of the hoisted object, the horizontal distance to the tower body, and the initial torque of the counterweight moving device, dynamically adjusts the position of the counterweight block 50 to generate the corresponding counter torque, thereby realizing load balancing. During the movement of the counterweight block 50, the system can also monitor the distance between adjacent counterweight blocks 50 in real time to prevent collisions and ensure the balance of the load torque on both sides of the jib 70 of the tower crane, improving the safety and efficiency of the operation; this mechanism enables the tower crane to quickly respond to changes in the hoisted object during operation, optimizes the distribution of the counterweight blocks 50, and ensures the safe and stable operation of the equipment.

[0095] In an embodiment, please refer to Figure 6 A control method of the above-mentioned automatic load balancing system of tower crane is also provided, including steps S110-S120.

[0096] S110, the main control unit 30 calculates the total load torque at the hoisted object end and the number of required counterweight blocks 50 and the counter torque according to the weight of the hoisted object collected by the gravity sensor 10, the horizontal distance of the hoisted object to the tower body, and the initial torque of the counterweight moving device, to form an instruction.

[0097] In an embodiment, please refer to Figure 7 The above-mentioned step S110 can include steps S111-S115.

[0098] S111, obtain the weight of the hoisted object and the horizontal distance of the hoisted object to the tower body through the sensor 10 and the encoder 20, and calculate the total load torque at the hoisted object end; S112, transmit the weight of the hoisted object and the horizontal distance of the hoisted object to the tower body to the main control unit 30; S113, the main control unit 30 calculates the maximum torque of the required counterweight according to the maximum design parameter; S114、When additional counterweight is needed, the number of individual and moving counterweight blocks 50 and their specific moving distance are calculated based on the additional required counterweight torque to generate instructions; S115、The main control unit 30 sends instructions to the sub-control unit to guide the movement of the counterweight blocks 50 along the slide rail 60, and continuously monitors and dynamically adjusts the position of the counterweight blocks 50 as needed.

[0099] Specifically, during the movement of the counterweight blocks 50, the main control unit 30 periodically performs discrete sampling of the load torque, and allows the counterweight blocks 50 to dynamically change the target position during movement according to the latest load torque information.

[0100] Wherein, the sampling interval of the discrete sampling is set according to the trolley speed.

[0101] During the movement of the counterweight blocks 50, the distance between the counterweight blocks 50 is monitored in real time by means of the laser sensor 80 to prevent collision, and the movement path is dynamically adjusted to adapt to load changes.

[0102] S120、The main control unit 30 sends instructions to the sub-control unit to control the movement of the corresponding counterweight blocks 50, dynamically adjust the movement distance of the corresponding counterweight blocks 50 on the slide rail 60 to generate the corresponding reverse torque, and feedback the pulley movement distance and the position of the counterweight blocks 50.

[0103] In this embodiment, in an embodiment, the control method of the tower crane automatic load balancing system realizes real-time response to changes in the weight and position of the hoisted object through a series of steps, and dynamically adjusts the position of the counterweight blocks 50 accordingly to ensure the safety and efficiency of the tower crane. Firstly, the system obtains the weight of the hoisted object and the horizontal distance from the hoisted object to the tower body through sensors 10 (including gravity sensors 10 and torque sensors 10) and encoders 20. Based on these data, the total load torque at the hoisted object end is calculated.

[0104] Next, the data of the weight of the hoisted object and the horizontal distance from the hoisted object to the tower body are transmitted to the main control unit 30, providing the main control unit 30 with the necessary input parameters.

[0105] The main control unit 30 calculates the required maximum counterweight torque according to the maximum design parameters of the crane, which is to determine the maximum reverse torque required under the most unfavorable conditions.

[0106] When it is found that the existing counterweight is insufficient to offset the torque generated by the hoisted object, the main control unit 30 calculates the number of individual counterweight blocks 50 and their specific moving distance based on the additional required counterweight torque. This process generates instructions for guiding the movement of the counterweight blocks 50.

[0107] The main control unit 30 sends the above-mentioned instruction to the sub-control unit, and the sub-control unit specifically performs the movement operation of the counterweight 50 along the slide rail 60. In this process, the main control unit 30 continuously performs discrete sampling of the load torque, and allows the target position of the counterweight 50 to be dynamically changed according to the latest load torque information. In particular, the sampling interval is set according to the trolley speed, ensuring the timeliness and accuracy of the adjustment. In addition, the distance between adjacent counterweights 50 is monitored in real time by using the laser sensor 80, preventing collision and dynamically adjusting the movement path to adapt to the change of the load.

[0108] After completing the initial calculation, the main control unit 30 sends an instruction to the sub-control unit, instructing it to control the movement of the corresponding counterweight 50. The sub-control unit dynamically adjusts the movement distance of the counterweight 50 on the slide rail 60 according to the received instruction to generate a corresponding reverse torque, thereby achieving load balancing. At the same time, the sub-control unit also feeds back the pulley movement distance and position information of each counterweight 50 to the main control unit 30 for subsequent monitoring and adjustment.

[0109] In summary, through accurate sensing, intelligent calculation and effective communication mechanism, automatic load balancing control is realized in the tower crane, thereby greatly improving the safety and efficiency of the operation.

[0110] It should be noted that the specific implementation process of the control method of the tower crane automatic load balancing system disclosed above can be clearly understood by those skilled in the art, and can refer to the corresponding description in the foregoing system embodiments. For the convenience and brevity of description, it will not be described here.

[0111] In the several embodiments of the present application, it should be understood that the disclosed device and method can be implemented in other ways. For example, the device embodiments described above are only schematic. The division of various units is only a logical function division, and other division manners can be used in actual implementation. For example, a plurality of units or components can be combined or integrated into another system, or some features can be ignored or not executed.

[0112] The steps in the method of the embodiments of the present application can be sequentially adjusted, combined and deleted according to actual needs. The units in the device of the embodiments of the present application can be combined, divided and deleted according to actual needs. In addition, each functional unit in each embodiment of the present application can be integrated in one processing unit, or each unit can exist physically, or two or more units can be integrated in one unit.

[0113] The integrated unit, if implemented in the form of a software function unit and sold or used as an independent product, can be stored in a storage medium. Based on such an understanding, the technical solutions of the present application essentially or say the part that contributes to the prior art, or the whole or part of the technical solutions can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes a plurality of instructions for causing a computer device (which can be a personal computer, a terminal, or a network device, etc.) to execute all or part of the steps of the method described in the various embodiments of the present application.

[0114] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of various equivalent modifications or replacements within the technical range disclosed by the present application, and these modifications or replacements should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. An automatic load balancing system for tower crane machinery, characterized in that, include: The system includes sensors, encoders, a counterweight moving device, and a main control unit. The sensors include a gravity sensor and a torque sensor. The gravity sensor and encoder are mounted on the hook. The counterweight moving device and torque sensor are mounted on the boom. The counterweight moving device includes a slide rail and several counterweight blocks that move on the slide rail. Each counterweight block includes a counterweight body, a pulley, and a sub-control unit. The sub-control unit is connected to the main control unit and is used to receive instructions from the main control unit to control the movement of the corresponding counterweight block and to provide feedback on the pulley movement distance and the position of the counterweight block. The main control unit is used to calculate the total load torque at the end of the load, the required number of counterweights, and the reverse torque based on the weight of the load, the horizontal distance from the load to the tower body, and the initial torque of the counterweight moving device. The sub-control unit dynamically adjusts the moving distance of the corresponding counterweights on the slide rail to generate the corresponding reverse torque, thereby achieving the balance of the load at the end of the tower crane. During the movement of the counterweight, the distance between adjacent counterweights is monitored in real time to adjust the movement of the counterweight and avoid collisions between adjacent counterweights.

2. The automatic load balancing system for tower crane machinery according to claim 1, characterized in that, The initial torque of the counterweight moving device includes the counterweight end fixing torque and the initial supply torque; The main control unit calculates the maximum additional torque required and the distance that a single counterweight should move, based on the load torque at the suspended end, the fixed torque at the counterweight end, and the initial torque provided by the counterweight slide rail, collected by the torque sensor. If the moving distance of a single counterweight is insufficient to meet the requirements, the main control unit calculates the number of counterweights that need to be moved and the exact moving distance of the last counterweight to compensate for the loss. It then sends a command to direct each counterweight to move to the corresponding target position on the slide rail to generate a corresponding reverse torque, ensuring load balance between the suspended end and the counterweight end.

3. The automatic load balancing system for tower crane machinery according to claim 1, characterized in that, The instruction includes a start time parameter, which is set to a delay interval after the current time to ensure that all the counterweights can receive the instruction within the specified time and perform the displacement operation at the same time.

4. The automatic load balancing system for tower crane machinery according to claim 1, characterized in that, The main control unit periodically samples the load torque discretely and allows the counterweight to dynamically change its target position based on the latest load torque information during movement.

5. The automatic load balancing system for tower crane machinery according to claim 1, characterized in that, The counterweight also includes a laser sensor and a drive motor. The laser sensor is used to prevent collisions between the counterweights. The drive motor is used to move the corresponding counterweight according to the position information provided by the encoder. When the sub-control unit receives the instruction sent by the main control unit, it converts the displacement requirement in the instruction into an encoder position and controls the drive motor to move the counterweight. During the movement, the distance between adjacent counterweights is monitored by a laser sensor to control the working state of the drive motor, so as to avoid collisions between adjacent counterweights and dynamically adjust the target position.

6. The control method for the automatic load balancing system of tower crane machinery as described in any one of claims 1 to 5, characterized in that, include: The main control unit calculates the total load torque at the end of the load, the required number of counterweights, and the reverse torque based on the weight of the load collected by the gravity sensor, the horizontal distance from the load to the tower, and the initial torque of the counterweight moving device, in order to generate instructions. The main control unit sends commands to the sub-control unit, which then controls the movement of the corresponding counterweight, dynamically adjusts the movement distance of the corresponding counterweight on the slide rail to generate the corresponding reverse torque, and provides feedback on the pulley movement distance and the position of the counterweight.

7. The control method for the automatic load balancing system of tower crane machinery according to claim 6, characterized in that, The main control unit calculates the total load torque at the load end, the required number of counterweights, and the reverse torque based on the weight of the suspended object, the horizontal distance from the suspended object to the tower body, and the initial torque of the counterweight moving device, in order to generate instructions, including: The weight of the suspended object and the horizontal distance from the suspended object to the tower are obtained through sensors and encoders, and the total load torque at the end of the suspended object is calculated. The weight of the suspended object and the horizontal distance from the suspended object to the tower body are transmitted to the main control unit. The main control unit calculates the maximum torque required for the counterweight based on the maximum design parameters; When additional counterweight is required, the number of individual counterweights to be moved and their specific moving distance are calculated based on the additional counterweight torque required, in order to generate instructions; The main control unit sends instructions to the sub-control unit, which guides the counterweight to move along the slide rail, and continuously monitors and dynamically adjusts the position of the counterweight as needed.

8. The control method for the automatic load balancing system of tower crane machinery according to claim 7, characterized in that, The main control unit sends commands to guide the counterweight to move along the slide rail, and continuously monitors and dynamically adjusts the position of the counterweight as needed, including: During the movement of the counterweight, the main control unit periodically performs discrete sampling of the load torque and allows the counterweight to dynamically change its target position based on the latest load torque information during the movement.

9. The control method for the automatic load balancing system of tower crane machinery according to claim 8, characterized in that, The sampling interval for the discrete sampling is set according to the speed of the vehicle.

10. The control method for the automatic load balancing system of tower crane machinery according to claim 7, characterized in that, The main control unit sends commands to the sub-control unit, which guides the counterweight to move along the slide rail, and continuously monitors and dynamically adjusts the position of the counterweight as needed, including: During the movement of the counterweights, the distance between the counterweights is monitored in real time by laser sensors to prevent collisions and dynamically adjust the movement path to adapt to load changes.

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