Tower crane load mass calculation method and device based on mass sensor calibration

Abstract

The embodiment of the invention provides a tower crane load mass calculation method and device based on mass sensor calibration, and the method comprises the steps: respectively obtaining first measurement results of a mass sensor at a plurality of variable-amplitude calibration positions of a calibration height when a tower crane is in a no-load state, and obtaining a zero-point reference reading according to the first measurement results; when the tower crane lifts the calibration load, second measurement results of the mass sensor are obtained at a plurality of variable-amplitude calibration positions of the calibration height respectively, and a calibration load reference reading is obtained according to the second measurement results; obtaining a calibration coefficient of the mass sensor according to the zero reference reading, the calibration load reference reading and the actual mass of the calibration load; and in the working process of the tower crane, the mass of the current load is obtained according to the calibration coefficient, the zero reference reading and the measurement result of the mass sensor. According to the technical scheme of the embodiment of the invention, the method solves a problem that the method is liable to be affected by mechanical vibration and environmental interference under a dynamic working condition, and guarantees the accuracy and stability of quality measurement.

Description

Technical Field

[0001] This application relates to the field of automatic control technology, and in particular to a method and apparatus for calculating the load mass of a tower crane based on mass sensor calibration. Background Technology

[0002] Mass sensors for tower cranes are used to monitor hook loads and are a core component for ensuring safe lifting and efficient operation.

[0003] However, in actual operation, changes in amplitude and lifting height, as well as environmental factors (such as mechanical vibration), can cause fluctuations in sensor readings, affecting measurement accuracy. Existing calibration methods are mostly based on static conditions and lack calibration mechanisms for dynamic operating conditions (such as amplitude and lifting).

[0004] In addition, single reading calibration may not effectively filter out noise, leading to zero drift in the empty state or excessive error in the loaded state, increasing the risk of overload or equipment failure. Summary of the Invention

[0005] In view of this, the embodiments of this application provide a method and apparatus for calculating the load mass of a tower crane based on mass sensor calibration. The method obtains zero-point reference readings and calibrated load reference readings at several variable amplitude calibration positions at the calibration height, and obtains calibration coefficients by combining the actual mass of the calibrated load. This solves the problem of being susceptible to mechanical vibration and environmental interference under dynamic working conditions, ensures the accuracy and stability of mass measurement, thereby reducing the risk of overload and improving the safety and operating efficiency of tower cranes under complex working conditions.

[0006] In a first aspect, embodiments of this application provide a method for calculating the load mass of a tower crane based on mass sensor calibration, comprising: when the tower crane is unloaded, moving the tower crane's boom to a calibration height, obtaining first measurement results of the mass sensor at several amplitude calibration positions of the boom, and obtaining a zero-point reference reading based on the first measurement results; when the tower crane lifts a calibration load of known mass, moving the tower crane's boom to the calibration height, obtaining second measurement results of the mass sensor at the several amplitude calibration positions of the boom, and obtaining a calibration load reference reading based on the second measurement results; obtaining a calibration coefficient of the mass sensor based on the zero-point reference reading, the calibration load reference reading, and the actual mass of the calibration load, wherein the calibration coefficient is used to calibrate the measurement results of the mass sensor to obtain the actual mass of the load; during the operation of the tower crane, obtaining the actual mass of the current load of the tower crane based on the calibration coefficient, the zero-point reference reading, and the measurement results of the mass sensor under the current load.

[0007] As described above, zero-point reference readings and calibrated load reference readings are obtained at several variable amplitude calibration positions at the calibration height. The calibration coefficient is obtained by combining the actual mass of the calibrated load. This solves the problem of being susceptible to mechanical vibration and environmental interference under dynamic working conditions, ensuring the accuracy and stability of mass measurement, thereby reducing the risk of overload and improving the safety and operating efficiency of tower cranes under complex working conditions.

[0008] In one possible implementation of the first aspect, after obtaining the calibration coefficient and before obtaining the actual mass of the current load of the tower crane, the method further includes: evaluating the calibration coefficient; and if the calibration coefficient does not meet the calibration requirements, increasing the number of luffing calibration positions, and re-obtaining the zero-point reference reading, the calibration load reference reading, and the calibration coefficient until the re-obtained calibration coefficient meets the calibration requirements.

[0009] Based on the above, the calibration coefficients are evaluated, and when the calibration requirements are not met, the amplitude variation position is increased to further reduce the impact of mechanical vibration and environmental interference, ensuring the accuracy and stability of mass measurement.

[0010] In one possible implementation of the first aspect, evaluating the calibration coefficient includes: obtaining a zero-point quality error, wherein the zero-point quality error is the product of the difference between each of the first measurement results and the zero-point reference reading and the calibration coefficient; and determining that the calibration coefficient does not meet the calibration requirements when the maximum value of the zero-point quality error is greater than a set error.

[0011] Therefore, by conducting zero-point evaluation of the calibration coefficients based on the zero-point mass error, the impact of mechanical vibration and environmental interference can be further reduced, ensuring the accuracy and stability of mass measurement.

[0012] In one possible implementation of the first aspect, evaluating the calibration coefficient includes: when the tower crane is unloaded, obtaining the measurement results of the mass sensor at several dynamic heights and several dynamic luffing positions of the tower crane's boom, respectively, as dynamic zero-point results; multiplying the difference between each value in the dynamic zero-point results and the zero-point reference reading with the calibration coefficient as the dynamic zero-point error; when the maximum value of the dynamic zero-point error is greater than the set error, determining that the calibration coefficient does not meet the calibration requirements.

[0013] Therefore, by conducting no-load dynamic calibration evaluation of the calibration coefficients based on dynamic zero-point error, the impact of mechanical vibration and environmental interference can be further reduced, ensuring the accuracy and stability of mass measurement.

[0014] In one possible implementation of the first aspect, evaluating the calibration coefficient includes: when the tower crane lifts a calibration load of known mass, taking the measurement results of the mass sensor obtained at several dynamic heights and at several dynamic luffing positions of the tower crane's boom as calibration dynamic measurement results; multiplying the difference between each value in the calibration dynamic measurement results and the zero-point reference reading with the calibration coefficient as the dynamic calibration mass; and determining that the calibration coefficient does not meet the calibration requirements when any value in the dynamic calibration mass deviates from the actual mass of the calibration load by a proportion greater than a set error proportion.

[0015] As described above, by evaluating the load accuracy calibration based on the relative error ratio of the calibration coefficients according to the dynamic calibration quality, the impact of mechanical vibration and environmental interference can be further reduced, ensuring the accuracy and stability of quality measurement.

[0016] In one possible implementation of the first aspect, the zero-point reference reading is the minimum value among the first measurement results, the calibration load reference reading is the minimum value among the second measurement results, and the calibration coefficient is the quotient of the actual mass of the calibration load divided by the difference between the calibration load reference reading and the zero-point reference reading; obtaining the mass of the current load of the tower crane based on the calibration coefficient, the zero-point reference reading, and the measurement result of the mass sensor under the current load includes: taking the product of the difference between the measurement result of the mass sensor under the current load and the zero-point reference reading and the calibration coefficient as the mass of the current load of the tower crane.

[0017] As shown above, the zero-point reference reading is the minimum value among the first measurement results, and the calibration load reference reading is the minimum value among the second measurement results, thereby eliminating all positive deviations caused by mechanical vibration and environmental interference.

[0018] In one possible implementation of the first aspect, after obtaining the calibration coefficient and before using the calibration coefficient during the operation of the tower crane, the method further includes: when the amplitude calibration position corresponding to the zero-point reference reading is different from the amplitude calibration position corresponding to the calibration load reference reading, increasing the number of amplitude calibration positions, and re-obtaining the zero-point reference reading, the calibration load reference reading, and the calibration coefficient of the mass sensor.

[0019] Therefore, when the amplitude calibration position corresponding to the zero-point reference reading is different from the amplitude calibration position corresponding to the calibration load reference reading, the number of amplitude calibration positions is increased to further reduce the impact of mechanical vibration and environmental interference.

[0020] In one possible implementation of the first aspect, the luffing calibration positions are evenly distributed on the slewing plane of the tower crane.

[0021] As a result, the amplitude calibration positions are evenly distributed on the slewing plane of the tower crane, further reducing the influence of wind direction on the measurement.

[0022] Secondly, embodiments of this application provide a tower crane load mass calculation device based on mass sensor calibration, comprising: an unloaded baseline module, used to move the tower crane's boom to a calibration height when the tower crane is unloaded, obtain the first measurement result of the mass sensor at several amplitude calibration positions of the boom, and obtain a zero-point reference reading based on the first measurement result; a calibration load module, used to move the tower crane's boom to the calibration height when the tower crane lifts a calibration load of known mass, obtain the second measurement result of the mass sensor at the several amplitude calibration positions of the boom, and obtain a calibration load reference reading based on the second measurement result; a calibration acquisition module, used to obtain the calibration coefficient of the mass sensor based on the zero-point reference reading, the calibration load reference reading, and the actual mass of the calibration load, wherein the calibration coefficient is used to calibrate the measurement result of the mass sensor to obtain the actual mass of the load; and a mass acquisition module, used to obtain the actual mass of the current load of the tower crane during the operation of the tower crane based on the calibration coefficient, the zero-point reference reading, and the measurement result of the mass sensor under the current load.

[0023] As described above, zero-point reference readings and calibrated load reference readings are obtained at several variable amplitude calibration positions at the calibration height. The calibration coefficient is obtained by combining the actual mass of the calibrated load. This solves the problem of being susceptible to mechanical vibration and environmental interference under dynamic working conditions, ensuring the accuracy and stability of mass measurement, thereby reducing the risk of overload and improving the safety and operating efficiency of tower cranes under complex working conditions.

[0024] In one possible implementation of the second aspect, it further includes: a calibration evaluation module, used to evaluate the calibration coefficient after obtaining the calibration coefficient and before obtaining the actual mass of the current load of the tower crane; when the calibration coefficient does not meet the calibration requirements, increasing the number of luffing calibration positions, and re-obtaining the zero-point reference reading, the calibration load reference reading and the calibration coefficient, until the re-obtained calibration coefficient meets the calibration requirements.

[0025] Based on the above, the calibration coefficients are evaluated, and when the calibration requirements are not met, the amplitude variation position is increased to further reduce the impact of mechanical vibration and environmental interference, ensuring the accuracy and stability of mass measurement.

[0026] In one possible implementation of the second aspect, the calibration evaluation module is specifically used to: obtain a zero-point quality error, wherein the zero-point quality error is the product of the difference between each of the first measurement results and the zero-point reference reading and the calibration coefficient; and determine that the calibration coefficient does not meet the calibration requirements when the maximum value of the zero-point quality error is greater than a set error.

[0027] Therefore, by conducting zero-point evaluation of the calibration coefficients based on the zero-point mass error, the impact of mechanical vibration and environmental interference can be further reduced, ensuring the accuracy and stability of mass measurement.

[0028] In one possible implementation of the second aspect, the calibration evaluation module is specifically used to: when the tower crane is unloaded, obtain the measurement results of the mass sensor at several dynamic heights and several dynamic luffing positions of the tower crane's boom, and use them as dynamic zero-point results; multiply the difference between each value in the dynamic zero-point results and the zero-point reference reading and the calibration coefficient as the dynamic zero-point error; when the maximum value of the dynamic zero-point error is greater than the set error, determine that the calibration coefficient does not meet the calibration requirements.

[0029] Therefore, by conducting no-load dynamic calibration evaluation of the calibration coefficients based on dynamic zero-point error, the impact of mechanical vibration and environmental interference can be further reduced, ensuring the accuracy and stability of mass measurement.

[0030] In one possible implementation of the second aspect, the calibration evaluation module is specifically used to include: when the tower crane lifts a calibration load of known mass, obtaining the measurement results of the mass sensor at several dynamic heights and several dynamic luffing positions of the tower crane's boom, respectively, as calibration dynamic measurement results; multiplying the difference between each value in the calibration dynamic measurement results and the zero-point reference reading with the calibration coefficient as the dynamic calibration mass; and determining that the calibration coefficient does not meet the calibration requirements when any value in the dynamic calibration mass deviates from the actual mass of the calibration load by a proportion greater than a set error proportion.

[0031] As described above, by evaluating the load accuracy calibration based on the relative error ratio of the calibration coefficients according to the dynamic calibration quality, the impact of mechanical vibration and environmental interference can be further reduced, ensuring the accuracy and stability of quality measurement.

[0032] In one possible implementation of the second aspect, the zero-point reference reading is the minimum value among the first measurement results, the calibration load reference reading is the minimum value among the second measurement results, and the calibration coefficient is the quotient of the actual mass of the calibration load divided by the difference between the calibration load reference reading and the zero-point reference reading; the mass acquisition module is specifically used to take the product of the difference between the mass sensor measurement result and the zero-point reference reading under the current load and the calibration coefficient as the mass of the tower crane's current load.

[0033] As shown above, the zero-point reference reading is the minimum value among the first measurement results, and the calibration load reference reading is the minimum value among the second measurement results, thereby eliminating all positive deviations caused by mechanical vibration and environmental interference.

[0034] In one possible implementation of the second aspect, the calibration evaluation module is further configured to increase the number of amplitude calibration positions and re-obtain the zero-point reference reading, the calibration load reference reading, and the calibration coefficient of the mass sensor when the amplitude calibration position corresponding to the zero-point reference reading is different from the amplitude calibration position corresponding to the calibration load reference reading.

[0035] Therefore, when the amplitude calibration position corresponding to the zero-point reference reading is different from the amplitude calibration position corresponding to the calibration load reference reading, the number of amplitude calibration positions is increased to further reduce the impact of mechanical vibration and environmental interference.

[0036] In one possible implementation of the second aspect, the luffing calibration positions are evenly distributed on the slewing plane of the tower crane.

[0037] As a result, the amplitude calibration positions are evenly distributed on the slewing plane of the tower crane, further reducing the influence of wind direction on the measurement.

[0038] Thirdly, embodiments of this application provide a computing device, including,

[0039] bus;

[0040] A communication interface, which is connected to the bus;

[0041] At least one processor connected to the bus; and

[0042] At least one memory is connected to the bus and stores program instructions that, when executed by the at least one processor, cause the at least one processor to perform the method described in any embodiment of the first aspect of this application.

[0043] Fourthly, embodiments of this application provide a computer-readable storage medium having program instructions stored thereon, which, when executed by a computer, cause the computer to perform the method described in any embodiment of the first aspect. Attached Figure Description

[0044] Figure 1 This is a flowchart illustrating an embodiment of a tower crane load mass calculation method based on mass sensor calibration according to this application.

[0045] Figure 2 This is a flowchart illustrating a second embodiment of the tower crane load mass calculation method based on mass sensor calibration according to this application.

[0046] Figure 3 This is a schematic diagram of the calibration height and amplitude calibration position for a second embodiment of the tower crane load mass calculation method based on mass sensor calibration according to this application;

[0047] Figure 4This is a flowchart illustrating the calibration coefficient evaluation method of Embodiment 2 of the tower crane load mass calculation method based on mass sensor calibration of this application;

[0048] Figure 5 This is a schematic diagram of a first embodiment of a tower crane load mass calculation device based on mass sensor calibration according to this application;

[0049] Figure 6 This is a schematic diagram of a second embodiment of a tower crane load mass calculation device based on mass sensor calibration according to this application;

[0050] Figure 7 This is a schematic diagram of the computing device of this application. Detailed Implementation

[0051] In the following description, references are made to “some embodiments,” which describe a subset of all possible embodiments. However, it is understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict.

[0052] In the following description, the terms “first, second, third, etc.” or module A, module B, module C, etc. are used not only to distinguish similar objects or different embodiments, but also do not represent a specific ordering of objects. It is understood that a specific order or sequence may be interchanged where permitted so that the embodiments of this application described herein can be implemented in an order other than that illustrated or described herein.

[0053] In the following description, the labels of the steps, such as S110, S120, etc., do not necessarily mean that the steps will be executed in this way. The order of the steps can be interchanged or executed simultaneously if permitted.

[0054] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0055] This application provides a method and apparatus for calculating the load mass of a tower crane based on mass sensor calibration. The method includes: when the tower crane is unloaded, moving the tower crane's boom to a calibration height, obtaining first measurement results from the mass sensor at several luffing calibration positions of the boom, and obtaining a zero-point reference reading based on the first measurement results; when the tower crane is lifting a calibration load, moving the tower crane's boom to the calibration height, obtaining second measurement results from the mass sensor at the several luffing calibration positions of the boom, and obtaining a calibration load reference reading based on the second measurement results; obtaining a calibration coefficient of the mass sensor based on the zero-point reference reading, the calibration load reference reading, and the actual mass; and during the tower crane's operation, obtaining the mass of the current load of the tower crane based on the calibration coefficient, the zero-point reference reading, and the measurement results of the mass sensor under the current load.

[0056] The technical solution of this application embodiment obtains zero-point reference readings and calibrated load reference readings at several variable amplitude calibration positions at the calibration height, and obtains calibration coefficients by combining the actual mass of the calibrated load. This solves the problem of being easily affected by mechanical vibration and environmental interference under dynamic working conditions, ensures the accuracy and stability of mass measurement, thereby reducing the risk of overload and improving the safety and operating efficiency of tower cranes under complex working conditions.

[0057] The embodiments of this application are described below with reference to the accompanying drawings. Figure 1 Embodiment 1 of a method for calculating the load mass of a tower crane based on mass sensor calibration, which is the subject of this application.

[0058] Figure 1 The flowchart of a method for calculating the load mass of a tower crane based on mass sensor calibration is shown in Embodiment 1, including steps S110 to S140.

[0059] S110: When the tower crane is unloaded, move the tower crane's boom to the calibrated height, obtain the first measurement results of the mass sensor at several luffing calibration positions of the boom, and obtain the zero-point reference reading based on the first measurement results.

[0060] For example, at a calibration height of half the tower height, there are three amplitude calibration positions, evenly distributed on the tower arm.

[0061] In some embodiments, the zero-point reference reading is the minimum value among the first measurement results to eliminate the influence of mechanical vibration and environmental interference; in other embodiments, the zero-point reference reading is the average value among the first measurement results.

[0062] In some embodiments, the luffing calibration positions are evenly distributed on the slewing plane of the tower crane, that is, several luffing calibration positions are evenly distributed on each evenly divided slewing angle of the tower arm to eliminate the influence of wind direction.

[0063] S120: When the tower crane lifts the calibrated load, the tower crane boom is moved to the calibrated height, and the second measurement results of the mass sensor are obtained at several variable amplitude calibration positions of the boom. The calibrated load reference reading is obtained based on the second measurement results.

[0064] The mass of the calibration load is known, and the coefficient of the mass sensor used to calibrate the tower crane is also known.

[0065] In some embodiments, the calibration load reference reading is the minimum value among the second measurement results to eliminate the effects of mechanical vibration and environmental interference; in other embodiments, the calibration load reference reading is the average of the various second measurement results.

[0066] S130: Obtain the calibration coefficient of the mass sensor based on the zero-point reference reading, the calibration load reference reading, and the actual mass of the calibration load.

[0067] The calibration coefficient of the mass sensor is used to calibrate the measurement results of the mass sensor in order to obtain the actual mass of the load.

[0068] In some embodiments, the calibration coefficient is obtained using a relative calibration method, which is the quotient of the actual mass of the calibration load divided by the difference between the calibration load reference reading and the zero-point reference reading.

[0069] S140: During the operation of the tower crane, the actual mass of the current load of the tower crane is obtained based on the calibration coefficient, the zero-point reference reading, and the measurement results of the mass sensor under the current load.

[0070] In some embodiments, the product of the difference between the mass sensor measurement result under the current load and the zero-point reference reading and the calibration coefficient is taken as the actual mass of the tower crane under the current load.

[0071] In some embodiments, after obtaining the calibration coefficients and before obtaining the actual mass of the current load on the tower crane, the calibration coefficients are evaluated. If the calibration coefficients do not meet the calibration requirements, the number of luffing calibration positions is increased, and the zero-point reference reading, calibration load reference reading, and calibration coefficients are obtained again until the re-obtained calibration coefficients meet the calibration requirements.

[0072] In some embodiments, the zero-point mass error is obtained, which is the product of the difference between each value in the first measurement result and the zero-point reference reading, and the calibration coefficient. When the maximum value of the zero-point mass error is greater than the set error, it is determined that the calibration coefficient does not meet the calibration requirements. By performing zero-point evaluation on the calibration coefficient based on the zero-point mass error, the influence of mechanical vibration and environmental interference is further reduced, ensuring the accuracy and stability of mass measurement.

[0073] In some embodiments, when the tower crane is unloaded, the measurement results of the mass sensor are obtained at several dynamic heights and at several dynamic luffing positions of the tower crane's jib, and these are used as dynamic zero-point results. The product of the difference between each value in the dynamic zero-point result and the zero-point reference reading and the calibration coefficient is used as the dynamic zero-point error. When the maximum value of the dynamic zero-point error is greater than the set error, it is determined that the calibration coefficient does not meet the calibration requirements. By performing no-load dynamic calibration evaluation of the calibration coefficient based on the dynamic zero-point error, the influence of mechanical vibration and environmental interference is further reduced, ensuring the accuracy and stability of mass measurement.

[0074] In some embodiments, when a tower crane lifts a calibration load of known mass, the measurement results of the mass sensor obtained at several dynamic heights and at several dynamic luffing positions of the tower crane's jib are used as the calibration dynamic measurement results. The product of the difference between each value in the calibration dynamic measurement results and the zero-point reference reading and the calibration coefficient is used as the dynamic calibration mass. When any value in the dynamic calibration mass deviates from the actual mass of the calibration load by a proportion greater than a set proportion, it is determined that the calibration coefficient does not meet the calibration requirements. By evaluating the load accuracy calibration based on the relative error of the calibration coefficients based on the dynamic calibration mass, the influence of mechanical vibration and environmental interference is further reduced, ensuring the accuracy and stability of mass measurement.

[0075] In some embodiments, the zero-point reference reading is the minimum value among the first measurement results, and the calibration load reference reading is the minimum value among the second measurement results. When the amplitude calibration position corresponding to the zero-point reference reading is different from the amplitude calibration position corresponding to the calibration load reference reading, the number of amplitude calibration positions is increased, and the zero-point reference reading, calibration load reference reading, and calibration coefficient of the mass sensor are obtained again to further reduce the impact of mechanical vibration and environmental interference problems.

[0076] In summary, Embodiment 1 of a tower crane load mass calculation method based on mass sensor calibration obtains zero-point reference readings and calibrated load reference readings at several variable amplitude calibration positions at the calibration height, and obtains calibration coefficients by combining them with the actual mass of the calibrated load. This solves the problem of susceptibility to mechanical vibration and environmental interference under dynamic working conditions, ensures the accuracy and stability of mass measurement, thereby reducing the risk of overload and improving the safety and operational efficiency of tower cranes under complex working conditions.

[0077] The following is combined Figures 2 to 4 Example 2 of a method for calculating the load mass of a tower crane based on mass sensor calibration is introduced.

[0078] Embodiment 2 of a method for calculating the load mass of a tower crane based on mass sensor calibration is a more specific implementation of Embodiment 1 of the method for calculating the load mass of a tower crane based on mass sensor calibration, and has all its advantages.

[0079] Figure 2 The flowchart of a second embodiment of a tower crane load mass calculation method based on mass sensor calibration is shown, including steps S210 to S260.

[0080] S210: When the tower crane is unloaded, move the tower crane's boom to 1 / 2 height, obtain the first measurement results of the mass sensor at the boom's luffing calibration position, and take the minimum value of the first measurement results as the zero-point reference reading.

[0081] Figure 3 A schematic diagram of the calibration height and amplitude calibration position of a second embodiment of a tower crane load mass calculation method based on mass sensor calibration is shown.

[0082] The calibration height is 1 / 2H. tower To reduce the impact of tower crane cables on calibration, luffing calibration positions are typically located at three representative positions—front, middle, and rear (e.g., luffing distances Lmin, Lmid, and Lmax)—to cover the typical operating range. These positions reflect common working conditions of tower cranes in actual lifting operations, ensuring the universality and robustness of the calibration. The number of luffing calibration positions may be increased, but they will all be evenly distributed along the tower jib.

[0083] In the unloaded state (load mass W = 0 tons), the mass sensor readings R were collected at the front, middle, and rear amplitude calibration positions. 0,1 R 0,2 R 0,3 (Unit: tons equivalent), and use formula (1) to select the minimum value as the zero-point reference reading.

[0084] R0=min(R 0，1 R 0，2 R 0，3 (1)

[0085] R0 represents the zero-point reference reading under no-load conditions, which is used to eliminate positive deviations caused by mechanical vibration, wind load, or sensor drift, and to ensure the accuracy of the zero baseline.

[0086] S220: When the tower crane lifts the calibration load, the tower crane boom is moved to 1 / 2 height, and the second measurement results of the mass sensor are obtained at the boom luffing calibration position respectively. The minimum value of the second measurement results is used as the calibration load reference reading.

[0087] Among them, the known calibrated load mass W is hung on the hook. ref (Unit: tons) When the mass sensor readings R are collected at the same three amplitude calibration positions (front, middle, and rear), the readings are taken. load,1 R load,2 R load,3(Unit: tons equivalent), and use formula (2) to select the minimum value as the calibration load reference reading.

[0088] R load =min(R) load，1 R load，2 R load，3 (2)

[0089] Among them, R load This indicates the calibration load reference reading under the calibration load condition. Selecting the minimum value aims to filter out reading fluctuations caused by dynamic operating conditions (such as luffing motion or hook sway) under load conditions, ensuring the stability of the calibration reference.

[0090] S230: The quotient of the actual mass of the calibrated load divided by the difference between the calibrated load reference reading and the zero-point reference reading is used as the calibration coefficient.

[0091] Among them, based on the zero-point reference reading R0 and the load reference reading R load and known rated load mass W ref The calibration coefficient κ is calculated using equation (3).

[0092]

[0093] Where κ (dimensionless) reflects the linear response characteristic between the mass sensor reading and the actual mass. If R... load If the value is R0, the calibration is invalid, and the sensor or operating condition settings need to be checked again.

[0094] S240: Evaluate the calibration coefficients.

[0095] When the calibration coefficient meets the calibration requirements, step S260 is executed. During the operation of the tower crane, the calibration coefficient is used to correct the mass sensor and obtain the mass of the current load of the tower crane. When the calibration coefficient does not meet the calibration requirements, step S250 is executed to add a variable amplitude calibration position and continue calibration.

[0096] For the scheme of evaluating the calibration coefficient, please refer to the calibration coefficient evaluation method in Example 2 of a method for calculating the load mass of a tower crane based on mass sensor calibration.

[0097] S250: Add amplitude calibration position and continue calibration.

[0098] Even after adding amplitude calibration positions, the amplitude calibration positions remain evenly distributed. After this step is executed, return to step S210 to continue calibration.

[0099] S260: During the operation of the tower crane, the actual mass of the current load of the tower crane is obtained based on the calibration coefficient, the zero-point reference reading, and the measurement results of the mass sensor under the current load.

[0100] During actual hoisting operations, the current mass sensor reading R is collected. C (Unit: ton equivalent), calculate the actual load mass W (unit: tons) using equation (4):

[0101] W=κ·(R C -R0) (4)

[0102] This formula uses the calibration coefficient κ and the zero-point reference R0 to determine the mass sensor reading R. C Convert to actual mass W to ensure the accuracy of the measurement results.

[0103] Figure 4 The flowchart of the calibration coefficient evaluation method of a second embodiment of a tower crane load mass calculation method based on mass sensor calibration is shown, including steps S2410 to S2460.

[0104] To verify the reliability of the calibration method, three evaluation steps are adopted: zero-point calibration evaluation, no-load dynamic calibration evaluation, and load accuracy calibration evaluation, to ensure that the measurement error is within the specified range. Specifically, steps S2410 and S2420 perform zero-point calibration evaluation; steps S2430 and S2440 perform no-load dynamic calibration evaluation; and steps S2450 and S2460 perform load accuracy calibration evaluation.

[0105] S2410: Obtain the zero-point quality error based on the first measurement result, the zero-point reference reading, and the calibration coefficient.

[0106] For each reading R under no-load conditions 0,i (i=1,2,3), calculate the zero-point mass error E using equation (5). zero，i .

[0107]

[0108] S2420: Determine whether the maximum value of the zero-point quality error is greater than the set error.

[0109] The maximum value of the zero-point mass error is E. zero，i The maximum value in the middle.

[0110] Specifically, if the maximum value of the zero-point mass error is greater than the set error, the calibration coefficient is determined to not meet the calibration requirements, and the evaluation ends. If the maximum value of the zero-point mass error is less than or equal to the set error, the accuracy of the zero-point calibration meets the requirements, and step S2430 is executed to continue the evaluation. For example, the set error is 0.2 tons.

[0111] S2430: When the tower crane is unloaded, the tower crane's boom is moved to several dynamic heights and the measurement results of the mass sensor are obtained at several dynamic luffing positions of the boom, and the dynamic zero-point error is calculated accordingly.

[0112] Among these, maintaining an unloaded state, at different dynamic lifting heights (e.g., H = 0.3H) tower 0.5H tower 0.8H tower ) and amplitude position (e.g., L) min ,L mid ,L max The dynamic readings are collected and used as the dynamic zero-point result R. dynamic The dynamic zero-point error W is calculated using equation (6). dynamic .

[0113] W dynamic =κ·(R) dynamic -R0) (6)

[0114] S2440: Determine whether the maximum value of the dynamic zero-point error is greater than the set error.

[0115] Among them, all W are required dynamic ≤ Set error to verify the stability of the calibration method under dynamic operating conditions.

[0116] Specifically, if the maximum value of the dynamic zero-point error is greater than the set error, the calibration coefficient is determined to not meet the calibration requirements, and the evaluation ends. If the maximum value of the dynamic zero-point error is less than or equal to the set error, step S2450 is executed to continue the evaluation.

[0117] S2450: When the tower crane lifts the calibration load, the measurement results of the mass sensor are obtained at several dynamic heights and at several dynamic luffing positions of the tower crane's boom, and the dynamic calibration mass is obtained accordingly.

[0118] Among these, when the tower crane lifts the rated load, at different dynamic lifting heights (e.g., H = 0.3H)... tower 0.5H tower 0.8H tower ) and amplitude position (e.g., L) min ,L mid ,L max Dynamic readings are collected and used as the calibration dynamic measurement result R. load,j (j=1,2,3,…), calculate the dynamic calibration quality W using equation (7). j .

[0119] W j =κ·(R) load，j -R0) (7)

[0120] S2460: Determine whether the deviation ratio between any value in the dynamic calibration mass and the actual mass of the calibration load is greater than the set error ratio.

[0121] Among them, the deviation ratio ε between each value in the dynamic calibration mass and the actual mass of the calibration load is calculated using equation (8). j (j = 1, 2, 3, ...), find all ε j Set an error percentage to ensure the accuracy of load measurements. For example, set the error percentage to 10%.

[0122]

[0123] In summary, Embodiment 2 of a tower crane load mass calculation method based on mass sensor calibration adds zero-point calibration evaluation, no-load dynamic calibration evaluation, and load accuracy calibration evaluation to the calibration coefficient, further reducing the impact of mechanical vibration and environmental interference, and ensuring the accuracy and stability of mass measurement.

[0124] The following is combined Figure 5 This paper introduces an embodiment of a tower crane load mass calculation device based on mass sensor calibration.

[0125] An embodiment of a tower crane load mass calculation device based on mass sensor calibration is provided. The method described in embodiment one of the tower crane load mass calculation methods based on mass sensor calibration has all its advantages.

[0126] Figure 5 The structure of a tower crane load mass calculation device based on mass sensor calibration is shown in Embodiment 1, including: no-load baseline module 510, calibration load module 520, calibration acquisition module 530 and mass acquisition module 540.

[0127] The no-load baseline module 510 is used to move the tower crane's jib to a calibrated height when the tower crane is unloaded, obtain the first measurement results from the mass sensor at several luffing calibration positions of the jib, and obtain the zero-point reference reading based on the first measurement results. For its working principle and advantages, please refer to step S110 of Embodiment 1 of a method for calculating tower crane load mass based on mass sensor calibration.

[0128] The calibration load module 520 is used to move the tower crane's jib to a calibration height when the tower crane lifts the calibration load, obtain the second measurement results from the mass sensor at several luffing calibration positions of the jib, and obtain the calibration load reference reading based on the second measurement results. For its working principle and advantages, please refer to step S120 of Embodiment 1 of a tower crane load mass calculation method based on mass sensor calibration.

[0129] The calibration acquisition module 530 is used to obtain the calibration coefficient of the mass sensor based on the zero-point reference reading, the calibration load reference reading, and the actual mass of the calibration load. For its working principle and advantages, please refer to step S130 of Embodiment 1 of a method for calculating the load mass of a tower crane based on mass sensor calibration.

[0130] The mass acquisition module 540 is used to obtain the mass of the current load of the tower crane during its operation, based on the calibration coefficient, zero-point reference reading, and the measurement results of the mass sensor under the current load. For its working principle and advantages, please refer to step S140 of Embodiment 1 of a method for calculating the load mass of a tower crane based on mass sensor calibration.

[0131] The following is combined Figure 6 This application presents a second embodiment of a tower crane load mass calculation device based on mass sensor calibration.

[0132] Embodiment 2 of a tower crane load mass calculation device based on mass sensor calibration executes the method described in Embodiment 2 of a tower crane load mass calculation method based on mass sensor calibration, and has all its advantages.

[0133] Figure 6 The structure of a second embodiment of a tower crane load mass calculation device based on mass sensor calibration is shown, including: an unloaded baseline module 610, a calibration load module 620, a calibration acquisition module 630, a calibration evaluation module 640, an amplitude adjustment module 650, and a mass acquisition module 660.

[0134] The no-load baseline module 610 is used to move the tower crane's boom to 1 / 2 height when the tower crane is unloaded, obtain the first measurement results of the mass sensor at the boom's luffing calibration position, and take the minimum value of the first measurement results as the zero-point reference reading. For its working principle and advantages, please refer to step S210 of Embodiment 2 of a method for calculating tower crane load mass based on mass sensor calibration.

[0135] The calibration load module 620 is used to move the tower crane's jib to half its height when the tower crane lifts the calibration load, and obtain the second measurement results from the mass sensor at the luffing calibration position of the jib. The minimum value among the second measurement results is used as the calibration load reference reading. For its working principle and advantages, please refer to step S220 of Embodiment Two of a method for calculating tower crane load mass based on mass sensor calibration.

[0136] The calibration acquisition module 630 is used to obtain the calibration coefficient by dividing the actual mass of the calibration load by the difference between the calibration load reference reading and the zero-point reference reading. For its working principle and advantages, please refer to step S230 of Embodiment 2 of a method for calculating the load mass of a tower crane based on mass sensor calibration.

[0137] The calibration evaluation module 640 is used to evaluate the calibration coefficients. For its working principle and advantages, please refer to step S240 of Example 2 of a method for calculating the load mass of a tower crane based on mass sensor calibration.

[0138] The luffing adjustment module 650 is used to add luffing calibration positions. For its working principle and advantages, please refer to step S250 of Example 2 of a method for calculating tower crane load mass based on mass sensor calibration.

[0139] The mass acquisition module 660 is used to obtain the actual mass of the current load of the tower crane during its operation, based on the calibration coefficient, zero-point reference reading, and the measurement results of the mass sensor under the current load. For its working principle and advantages, please refer to step S260 of Embodiment Two of a method for calculating the load mass of a tower crane based on mass sensor calibration.

[0140] This application also provides a computing device, which will be described below in conjunction with... Figure 7 Detailed introduction.

[0141] The computing device 700 includes a processor 710, a memory 720, a communication interface 730, and a bus 740.

[0142] It should be understood that the communication interface 730 in the computing device 700 shown in the figure can be used to communicate with other devices.

[0143] The processor 710 can be connected to the memory 720. The memory 720 can be used to store the program code and data. Therefore, the memory 720 can be a storage unit inside the processor 710, an external storage unit independent of the processor 710, or a component that includes both the storage unit inside the processor 710 and the external storage unit independent of the processor 710.

[0144] Optionally, the computing device 700 may also include a bus 740. The memory 720 and communication interface 730 can be connected to the processor 710 via the bus 740. The bus 740 can be a Peripheral Component Interconnect (PCI) bus or an Extended Industry Standard Architecture (EISA) bus, etc. The bus 740 can be divided into an address bus, a data bus, a control bus, etc. For ease of illustration, only one line is used in this figure, but this does not mean that there is only one bus or one type of bus.

[0145] It should be understood that in the embodiments of this application, the processor 710 may be a central processing unit (CPU). The processor may also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or any conventional processor. Alternatively, the processor 710 may employ one or more integrated circuits to execute relevant programs to implement the technical solutions provided in the embodiments of this application.

[0146] The memory 720 may include read-only memory and random access memory, and provides instructions and data to the processor 710. A portion of the processor 710 may also include non-volatile random access memory. For example, the processor 710 may also store device type information.

[0147] When the computing device 700 is running, the processor 710 executes computer execution instructions stored in the memory 720 to perform the operation steps of each method embodiment.

[0148] It should be understood that the computing device 700 according to the embodiments of this application can correspond to the corresponding subject in executing the methods according to the various embodiments of this application, and the above and other operations and / or functions of each module in the computing device 700 are respectively for implementing the corresponding processes of the methods of this embodiment. For the sake of brevity, they will not be described in detail here.

[0149] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0150] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0151] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0152] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0153] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0154] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0155] This application also provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, is used to perform the operation steps of the various method embodiments.

[0156] The computer storage medium in this application embodiment can be any combination of one or more computer-readable media. The computer-readable medium can be a computer-readable signal medium or a computer-readable storage medium. For example, a computer-readable storage medium can be, but is not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples of computer-readable storage media (a non-exhaustive list) include electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this document, a computer-readable storage medium can be any tangible medium that contains or stores a program that can be used by or in conjunction with an instruction execution system, apparatus, or device.

[0157] Computer-readable signal media may include data signals transmitted in baseband or as part of a carrier wave, carrying computer-readable program code. Such transmitted data signals may take various forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination thereof. Computer-readable signal media may also be any computer-readable medium other than computer-readable storage media, which can send, transmit, or transmit programs for use by or in connection with an instruction execution system, apparatus, or device.

[0158] The program code contained on a computer-readable medium may be transmitted using any suitable medium, including, but not limited to, wireless, wire, optical fiber, RF, etc., or any suitable combination thereof.

[0159] Computer program code for performing the operations of this application can be written in one or more programming languages ​​or a combination thereof, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, and conventional procedural programming languages ​​such as "C" or similar programming languages. The program code can be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving remote computers, the remote computer can be connected to the user's computer via any type of network, including a local area network (LAN) or a wide area network (WAN), or it can be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0160] Note that the above are merely preferred embodiments and the technical principles employed in this application. Those skilled in the art will understand that this application is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of this application. Therefore, although this application has been described in detail through the above embodiments, this application is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of this application, all of which fall within the scope of protection of this application.

Claims

1. A method for calculating the load mass of a tower crane based on mass sensor calibration, characterized in that, include: When the tower crane is unloaded, the tower crane's boom is moved to the calibrated height, and the first measurement results of the tower crane's mass sensor are obtained at several luffing calibration positions of the boom. The zero-point reference reading is obtained based on the first measurement results. When the tower crane lifts a calibrated load of known mass, the tower crane's boom is moved to the calibrated height, and the second measurement results of the mass sensor are obtained at the several luffing calibration positions of the boom, and the calibrated load reference reading is obtained based on the second measurement results. The calibration coefficient of the mass sensor is obtained based on the zero-point reference reading, the calibration load reference reading, and the actual mass. During the operation of the tower crane, the actual mass of the current load of the tower crane is obtained based on the calibration coefficient, the zero-point reference reading, and the measurement results of the mass sensor under the current load.

2. The method according to claim 1, characterized in that, Before obtaining the actual mass of the tower crane's current load, the following steps are also included: The calibration coefficients are evaluated; If the calibration coefficients do not meet the calibration requirements, increase the number of amplitude calibration positions and re-obtain the zero-point reference reading, calibration load reference reading, and the calibration coefficients until the re-obtained calibration coefficients meet the calibration requirements.

3. The method according to claim 2, characterized in that, The evaluation of the calibration coefficients includes: The zero-point quality error is obtained, which is the product of the difference between each of the first measurement results and the zero-point reference reading and the calibration coefficient. If the maximum value of the zero-point quality error is greater than the set error, it is determined that the calibration coefficient does not meet the calibration requirements.

4. The method according to claim 2, characterized in that, The evaluation of the calibration coefficients includes: When the tower crane is unloaded, the measurement results of the mass sensor are obtained at several dynamic heights and at several dynamic luffing positions of the tower crane's boom, and are used as dynamic zero-point results. The product of the difference between each value in the dynamic zero-point result and the zero-point reference reading and the calibration coefficient is taken as the dynamic zero-point error. If the maximum value of the dynamic zero-point error is greater than the set error, it is determined that the calibration coefficient does not meet the calibration requirements.

5. The method according to claim 2, characterized in that, The evaluation of the calibration coefficients includes: When the tower crane lifts the calibration load, the measurement results of the mass sensor obtained at several dynamic heights and at several dynamic luffing positions of the tower crane boom are used as calibration dynamic measurement results. The product of the difference between each value in the calibration dynamic measurement result and the zero-point reference reading and the calibration coefficient is taken as the dynamic calibration quality. If any value in the dynamic calibration quality deviates from the actual quality of the calibration load by a proportion greater than the set error proportion, it is determined that the calibration coefficient does not meet the calibration requirements.

6. The method according to claim 1, characterized in that, The zero-point reference reading is the minimum value among the first measurement results, the calibration load reference reading is the minimum value among the second measurement results, and the calibration coefficient is the quotient of the actual mass of the calibration load divided by the difference between the calibration load reference reading and the zero-point reference reading. Based on the calibration coefficient, zero-point reference reading, and the measurement results of the mass sensor under the current load, the mass of the tower crane under the current load is obtained, including: The mass of the tower crane under the current load is the product of the difference between the measurement result of the mass sensor under the current load and the zero-point reference reading and the calibration coefficient.

7. The method according to claim 6, characterized in that, The process includes, after obtaining the calibration coefficient and before using the calibration coefficient during the operation of the tower crane: When the amplitude calibration position corresponding to the zero-point reference reading is different from the amplitude calibration position corresponding to the calibration load reference reading, the number of amplitude calibration positions is increased, and the zero-point reference reading, calibration load reference reading, and calibration coefficient of the mass sensor are obtained again.

8. A tower crane load mass calculation device based on mass sensor calibration, characterized in that, include: The no-load baseline module is used to move the tower crane's boom to a calibrated height when the tower crane is unloaded, obtain the first measurement results of the mass sensor at several luffing calibration positions of the boom, and obtain the zero-point reference reading based on the first measurement results. The calibration load module is used to move the tower crane's boom to a calibration height when the tower crane lifts a calibration load of known mass, obtain the second measurement results of the mass sensor at the several luffing calibration positions of the boom, and obtain the calibration load reference reading based on the second measurement results; The calibration acquisition module is used to obtain the calibration coefficient of the mass sensor based on the zero-point reference reading, the calibration load reference reading, and the actual mass. The mass acquisition module is used to obtain the actual mass of the tower crane under the current load during the operation of the tower crane, based on the calibration coefficient, the zero-point reference reading, and the measurement results of the mass sensor under the current load.

9. A computing device, characterized in that, include, bus; A communication interface, which is connected to the bus; At least one processor is connected to the bus; as well as At least one memory connected to the bus and storing program instructions that, when executed by the at least one processor, cause the at least one processor to perform the method of any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, It stores program instructions that, when executed by a computer, cause the computer to perform the method of any one of claims 1 to 7.

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