Portal crane state intelligent monitoring and early warning system and method

Abstract

The invention relates to the technical field of safety monitoring of hoisting machinery, and discloses an intelligent monitoring and early warning system and method for the state of a portal crane, and the system comprises a plurality of state sensors which are arranged at key parts of the portal crane and are used for detecting the real-time state of the portal crane; the signal acquisition and logic processing unit is configured to acquire signals of the state sensor and execute logic judgment and comprehensive control; and the information display and man-machine interaction unit is configured to display the state information and alarm prompt of each monitoring point in real time according to the logic judgment and comprehensive control result of the signal acquisition and logic processing unit. The device can be widely applied to hydropower stations, ports, workshops and other occasions where portal cranes are used, and is suitable for real-time monitoring and rapid display of the key safety state of the portal crane under the severe weather conditions of strong wind, rainstorm, thunder and lightning and the like.

Description

Technical Field

[0001] This invention relates to the field of safety monitoring technology for lifting machinery, and in particular to an intelligent monitoring and early warning system and method for gantry crane status. Background Technology

[0002] In responding to warnings of severe weather such as strong winds, heavy rain, and lightning, the inspection of gantry cranes typically requires focusing on the following items: whether the main power supply to the gantry crane is disconnected; whether the trolley locking mechanisms (such as rail clamps and ground anchors) are engaged; whether the driver's cab doors and windows are closed; whether the trolley machine room door is closed; whether the trolley locking mechanisms (such as rail supports and trolley ground anchors) are engaged; whether the safety brakes of the hoisting mechanism are in the braking state; and whether the gantry crane's grounding is reliable. These checks effectively prevent the gantry crane or trolley from being blown away or even overturned by strong winds, avoid heavy rain from seeping into the driver's cab or trolley machine room and damaging electrical equipment, and prevent the risk of lightning strike damage to equipment due to poor lightning protection grounding.

[0003] In responding to warnings and responses to severe weather events such as strong winds, heavy rains, and thunderstorms, the current gantry crane inspection model presents numerous inconveniences and safety hazards, primarily in the following aspects: First, the gantry cranes are tall and exposed, requiring inspection personnel to climb to the top for manual inspections during extreme weather conditions such as strong winds, thunderstorms, and heavy rains—a highly dangerous process. Especially during strong winds, heavy rains, or thunderstorms, climbing and remaining at heights not only carries the risk of falls but also the possibility of being struck by lightning. Second, if severe weather warnings occur at night, limited lighting obstructs visibility, significantly increasing the difficulty of equipment identification and status confirmation. Third, the current inspection method relies mainly on manual checks of various mechanisms (such as main power supply, locking devices, brakes, doors and windows, grounding, etc.), which is time-consuming and inefficient. For multiple gantry cranes located on the dam crest, each crane must be checked individually, which is not only labor-intensive but also makes it difficult to guarantee a fast response time. Meanwhile, the status of some equipment (such as grounding reliability) is difficult to confirm visually and requires verification by special instruments or on-site operation. However, these testing processes are almost impossible to carry out safely in heavy rain or lightning conditions.

[0004] In summary, the current manual inspection mode has problems such as high risk, low efficiency, insufficient reliability, and untimely response in severe weather warning response. It is urgent to improve it through remote monitoring, intelligent sensing and other means to improve operational efficiency and safety level. Summary of the Invention

[0005] To address the problems of high risk, low efficiency, and difficulty in confirming the status of gantry cranes during early warning and inspection in severe weather, this invention proposes an intelligent monitoring and early warning system and method for gantry crane status. It can be widely applied in hydropower stations, ports, factories, and other applications where gantry cranes are used. It is suitable for real-time monitoring and rapid display of the critical safety status of gantry cranes under severe weather conditions such as strong winds, heavy rain, and lightning.

[0006] The technical solution adopted in this invention is as follows: A gate operator status intelligent monitoring and early warning system, comprising: Several status sensors are installed at key parts of the door operator to detect the real-time status of the door operator; the real-time status of the door operator includes power status, lock status, brake status, door and window closure status, and grounding status; The signal acquisition and logic processing unit is configured to acquire status sensor signals and perform logical judgments and integrated control. The information display and human-computer interaction unit is configured to display the status information and alarm prompts of each monitoring point in real time based on the logical judgment and comprehensive control results of the signal acquisition and logic processing unit.

[0007] Furthermore, the signal acquisition and logic processing unit is installed inside the gantry crane machine room; the top of the gantry crane machine room is equipped with a lightning rod and a lightning protection grounding monitoring device, which is configured to detect the on / off state and grounding resistance status of the lightning protection system in real time, and output signals to the signal acquisition and logic processing unit.

[0008] Furthermore, the gantry crane trolley room is also equipped with a lifting mechanism and a control system; the lifting mechanism is equipped with a height detection device, which is configured to detect the position of the lifting mechanism hook and realize hook height monitoring; the gantry crane's safety brake is equipped with a brake detection device, which is configured to detect the brake action status.

[0009] Furthermore, the signal acquisition and logic processing unit acquires signals from the electrical, mechanical, safety protection, and environmental components. The electrical signals include the main circuit breaker's engaged state and the main contactor's state; the mechanical signals include the safety brake's holding state and the wind-resistant fixing device's engaged state; the safety protection signals include the driver's cab door, window, and engine room door's closed state signals and the lifting height signal; and the environmental signals include wind speed signals and lightning protection grounding resistance signals.

[0010] Furthermore, the information display and human-computer interaction unit is a touch screen terminal, installed at the lower beam of the gantry crane, and communicates with the signal acquisition and logic processing unit via an Ethernet interface.

[0011] Furthermore, the intelligent monitoring and early warning system for the gantry crane status also includes a wind speed monitoring unit, which is configured to detect the wind speed signal of the environment in which the gantry crane is located and to detect the activation status of the wind-resistant fixing device.

[0012] Furthermore, the wind-resistant fixing device includes a trolley ground anchor, a trolley ground anchor, a trolley rail support, and a trolley rail clamp. Each wind-resistant fixing device is equipped with a detection switch for detecting whether it is in the activated state.

[0013] Furthermore, the intelligent monitoring and early warning system for the gantry crane status also includes a lightning monitoring unit, which is configured to generate risk alerts based on the lightning protection grounding status of the gantry crane and can send early warning signals through the monitoring center.

[0014] Furthermore, the intelligent monitoring and early warning system for gantry crane status also includes a remote communication unit, which is configured to upload the status data of multiple gantry cranes to the monitoring center to realize centralized monitoring and management of multiple gantry cranes.

[0015] A method for intelligent monitoring and early warning of gantry crane status, comprising: The real-time status of the door operator is detected by several status sensors installed in key parts of the door operator, including power status, lock status, brake status, door and window closing status, and grounding status. Collects status sensor signals and performs logical judgments and integrated control; Based on the logical judgment and comprehensive control results, the status information and alarm prompts of each monitoring point are displayed in real time.

[0016] The beneficial effects of this invention are as follows: This invention achieves automatic data acquisition and centralized display of the gantry crane's operational and safety status by installing status sensors at key components. A signal acquisition and logic processing unit performs logical judgment and comprehensive control, and an information display and human-machine interaction unit shows the status information and alarm prompts of all inspectable components. This invention can be widely applied in hydropower stations, ports, factories, and other applications using gantry cranes, and is suitable for real-time monitoring and rapid display of critical safety status of gantry cranes under severe weather conditions such as strong winds, heavy rain, and lightning. The specific advantages of this invention are as follows.

[0017] 1. Significantly improves inspection safety. Inspection personnel no longer need to climb the gantry crane in dangerous conditions such as strong winds, heavy rain, or lightning. They can check the status from the ground, avoiding the risks of working at heights and lightning strikes.

[0018] 2. Significantly improves inspection efficiency. This invention can automatically summarize and display the status of the gantry crane in real time. Inspection personnel can complete quick inspections simply by using a touch screen, greatly reducing labor intensity and inspection time.

[0019] 3. Improve the timeliness of early warning response. When a severe weather warning is issued, the status of all gantry cranes can be confirmed in a short time, gaining valuable time for emergency response such as wind, lightning, and rain protection.

[0020] 4. Avoid human error and missed detection. This invention uses sensors to automatically detect the status, avoiding misjudgments and missed detections caused by insufficient lighting at night, inclement weather, or human negligence, thus improving the accuracy and reliability of information.

[0021] 5. Facilitates centralized management and record traceability. The signal acquisition and logic processing unit and the information display and human-machine interaction unit can be expanded with network functionality to achieve centralized monitoring and data recording of multiple gantry cranes, providing data support for subsequent safety management and equipment maintenance.

[0022] 6. Possesses scalability and potential for intelligent upgrades. The system can be further integrated with modules such as lightning monitoring, wind speed alarms, and remote monitoring, gradually realizing a systematic management of intelligent early warning and response systems. Attached Figure Description

[0023] Figure 1 This is a front view of the intelligent monitoring and early warning system for the gate operator status according to Embodiment 3 of the present invention.

[0024] Figure 2 This is a side view of the intelligent monitoring and early warning system for the gate operator status according to Embodiment 3 of the present invention.

[0025] Figure 3 This is a top view of the intelligent monitoring and early warning system for the gate operator status according to Embodiment 3 of the present invention.

[0026] Figure 4 This is a circuit diagram of the power supply in Embodiment 3 of the present invention.

[0027] Figure 5 This is a circuit diagram of the signal acquisition and logic processing unit in Embodiment 3 of the present invention.

[0028] Figure 6 This is a circuit diagram of the analog signal acquisition unit in Embodiment 3 of the present invention. Detailed Implementation

[0029] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments are now described. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention; that is, the described embodiments are only a part of the embodiments of the invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0030] Example 1 This embodiment provides a door operator status intelligent monitoring and early warning system, including: Several status sensors are installed at key parts of the door operator to detect the real-time status of the door operator; the real-time status of the door operator includes power status, lock status, brake status, door and window closure status, and grounding status; The signal acquisition and logic processing unit is configured to acquire status sensor signals and perform logical judgments and integrated control. The information display and human-computer interaction unit is configured to display the status information and alarm prompts of each monitoring point in real time based on the logical judgment and comprehensive control results of the signal acquisition and logic processing unit.

[0031] It should be noted that by precisely deploying sensors in multiple locations, the core status dimensions of the gantry crane can be fully covered, ensuring that no critical information is missed; the efficient operation of the signal acquisition and logic processing unit enables rapid response and accurate judgment of status signals, providing a reliable basis for subsequent control and prompts; the information display and human-machine interaction unit allows operators to keep abreast of the gantry crane's status in real time, respond to abnormal situations in a timely manner, effectively reduce the risk of malfunctions, and ensure the safe and stable operation of the gantry crane.

[0032] Preferably, the signal acquisition and logic processing unit is installed inside the gantry crane machine room; the top of the gantry crane machine room is equipped with a lightning rod and a lightning protection grounding monitoring device, which is configured to detect the on / off state of the lightning protection system and the grounding resistance in real time, and output signals to the signal acquisition and logic processing unit.

[0033] Specifically, taking into account the spatial layout and signal transmission convenience of the gantry crane machine room, the signal acquisition and logic processing unit is fixedly installed in a dry location inside the machine room that is not easily affected by vibration; the lightning rod is stably installed according to the top structural characteristics of the gantry crane machine room; the lightning protection grounding monitoring device is linked with the grounding system of the lightning rod and the gantry crane to continuously monitor the circuit continuity of the lightning protection system and the dynamic changes in grounding resistance; once the relevant status data is acquired, the corresponding electrical signal is immediately transmitted to the signal acquisition and logic processing unit.

[0034] It should be noted that installing the signal acquisition and logic processing unit inside the gantry crane's machine room can avoid physical damage and signal interference caused by the external environment, ensuring the stability and service life of the unit. The combined use of the lightning rod and the lightning protection grounding monitoring device can capture the working status of the lightning protection system in real time, promptly detect abnormal continuity or grounding resistance, and enable the system to respond quickly through signal transmission, preventing the gantry crane from being damaged by lightning strikes during thunderstorms and improving the environmental adaptability and operational safety of the gantry crane.

[0035] Preferably, the gantry crane trolley room is also equipped with a hoisting mechanism and a control system; the hoisting mechanism is equipped with a height detection device, which is configured to detect the position of the hoisting mechanism hook and realize hook height monitoring; the gantry crane's safety brake is equipped with a brake detection device, which is configured to detect the brake action status.

[0036] Specifically, the hoisting mechanism and control system are installed in preset positions in the gantry crane trolley room according to the load requirements and operating logic of the gantry crane. The height detection device is connected to the hook transmission structure of the hoisting mechanism. By sensing the movement trajectory and position changes of the transmission structure, it captures the height information of the hook in real time and transmits the information to the control system. The brake detection device is installed at the brake actuator of the safety brake. It monitors the opening and closing action and locking degree of the brake in real time and simultaneously feeds back the detection results to the relevant control unit.

[0037] It should be noted that the rational layout of the hoisting mechanism and control system ensures the accuracy and reliability of the gantry crane's hoisting operations; the height detection device can monitor the hook height in real time, avoiding safety hazards such as collisions and overloads caused by excessive lifting or lowering of the hook, and ensuring the standardization of hoisting operations; the brake detection device can promptly detect abnormal brake actions, such as incomplete closure or untimely opening and closing, and through feedback signals, the control system can quickly take braking adjustment or alarm measures to ensure the braking effect of the safety brake and further improve the safety of the gantry crane's hoisting and braking processes.

[0038] Preferably, the signal acquisition and logic processing unit acquires signals from the electrical, mechanical, safety protection, and environmental components. The electrical signals include the main circuit breaker's engaged state and the main contactor's state; the mechanical signals include the safety brake's holding state and the wind-resistant fixing device's engaged state; the safety protection signals include the driver's cab door, window, and engine room door's closed state signals and the lifting height signal; and the environmental signals include wind speed signals and lightning protection grounding resistance signals.

[0039] Specifically, the signal acquisition and logic processing unit establishes connections with the gantry crane's electrical system, mechanical structure, safety protection components, and environmental monitoring components through preset signal acquisition interfaces and lines. For the electrical components, it focuses on acquiring the engagement / disengagement status of the main circuit breaker and the operating status signals of the main contactor. For the mechanical components, it focuses on capturing the holding status of the safety brake and the operational status signals of the wind-resistant fixing device. For the safety protection components, it acquires the closing status of the driver's cab doors, windows, and machine room doors, as well as the height signals of the hoisting mechanism. For the environmental components, it collects relevant signals such as wind speed and lightning protection grounding resistance in the environment where the gantry crane is located. During the acquisition process, the signals are initially sorted according to classification logic before subsequent processing.

[0040] It should be noted that classifying the data acquisition objects into electrical, mechanical, safety protection, and environmental categories makes signal acquisition more targeted and systematic, avoiding mutual interference between different types of signals. Comprehensive coverage of signal acquisition for all key components allows the system to fully grasp the operating status, mechanical performance, safety protection status, and surrounding environmental conditions of the gantry crane. This provides a comprehensive and multi-dimensional data source for logical judgment and integrated control, thereby improving the accuracy of system judgment and the effectiveness of control, and reducing the risk of misjudgment or omission of faults due to missing signals.

[0041] Preferably, the information display and human-machine interaction unit is a touch screen terminal, installed at the lower crossbeam of the gantry crane, and communicates with the signal acquisition and logic processing unit via an Ethernet interface. Specifically, a touch screen terminal adapted to the gantry crane's operating environment is selected as the information display and human-machine interaction unit. Based on the structural characteristics of the lower crossbeam of the gantry crane and the ease of operation for the operator, the touch screen terminal is fixedly installed in an easily observable and easily operable position on the crossbeam. The touch screen terminal establishes a stable communication connection with the signal acquisition and logic processing unit through a preset Ethernet interface line, and receives status data, logic judgment results, and control commands transmitted by the signal acquisition and logic processing unit in real time according to a preset communication protocol. At the same time, it allows the operator to perform simple parameter settings or command input through the touch screen.

[0042] It should be noted that the installation location of the touchscreen terminal balances ease of observation and operational safety, allowing operators to quickly obtain information and interact without affecting the operation of the gantry crane; the Ethernet interface communication method ensures the stability and efficiency of data transmission, reducing data delays or loss, and making status information display and alarm prompts more timely; the touchscreen's interactive form is intuitive and easy to understand, lowering the barrier to entry for operators, improving the efficiency of human-machine interaction, and enabling operators to quickly respond to system prompts, ensuring smooth gantry crane operations.

[0043] Preferably, the intelligent monitoring and early warning system for the gantry crane status further includes a wind speed monitoring unit, which is configured to detect the wind speed signal of the environment in which the gantry crane is located and to detect the activation status of the wind-resistant fixing device.

[0044] Specifically, the wind speed monitoring unit is installed on the top of the gantry crane or other unobstructed locations that can accurately sense the ambient wind speed. It captures the changes in wind speed in the environment in real time through built-in sensing components. At the same time, it establishes communication with the status detection components of each wind-resistant fixing device through signal connection lines to obtain real-time status information on whether the wind-resistant fixing device is in use. After the wind speed monitoring unit initially integrates the collected wind speed signals and the status signals of the wind-resistant fixing devices, it transmits them to the signal acquisition and logic processing unit.

[0045] It should be noted that the reasonable installation position of the wind speed monitoring unit ensures the accuracy of wind speed detection and avoids the influence of obstructions on wind speed perception. The unit also detects both wind speed and the status of wind-resistant fixing devices, enabling the system to have a comprehensive understanding of the wind load environment faced by the gantry crane and its own wind resistance preparedness. When the wind speed reaches the preset risk threshold or the wind-resistant fixing devices are not put into operation in time, the system can quickly trigger an early warning or control command to prevent the gantry crane from tipping over or shifting due to excessive wind force, thereby improving the operational stability and safety of the gantry crane in complex wind environments.

[0046] Preferably, the wind-resistant fixing device includes a main trolley ground anchor, a trolley ground anchor, a trolley rail support, and a main trolley rail clamp. Each wind-resistant fixing device is equipped with a detection switch for detecting whether it is in the activated state.

[0047] Specifically, the gantry crane ground anchor, trolley ground anchor, trolley rail support, and gantry crane rail clamp are installed in corresponding parts of the gantry crane according to the structural distribution and wind resistance requirements of the gantry crane. The detection switch is connected to the actuator of each wind-resistant fixing device. When the wind-resistant fixing device performs an activation action, such as ground anchor fixing, rail support, or rail clamp clamping, the detection switch senses the position or state change of the actuator, generates the corresponding activation status signal, and transmits the signal to the wind speed monitoring unit or the signal acquisition and logic processing unit.

[0048] It should be noted that the combination of various wind-resistant fixing devices can improve the wind resistance of the gantry crane from different dimensions and adapt to the wind resistance requirements under different wind speed conditions. The detection switches equipped with each device can accurately capture its activation status, avoiding wind resistance failure due to incomplete device activation or misoperation. Through signal transmission, the system can monitor the wind resistance preparation status in real time, providing a reliable basis for the system to judge the operational safety of the gantry crane under wind conditions, and further enhancing the wind resistance protection effect of the gantry crane.

[0049] Preferably, the intelligent monitoring and early warning system for the gantry crane status also includes a lightning monitoring unit, which is configured to generate risk alerts based on the lightning protection grounding status of the gantry crane and can send early warning signals through the monitoring center.

[0050] Specifically, the lightning monitoring unit establishes a signal connection with the lightning protection grounding monitoring device of the gantry crane, receives the lightning protection grounding status signal in real time, and at the same time, through the built-in lightning risk assessment logic, combined with the common patterns of local lightning weather and the characteristics of the gantry crane's operating environment, assesses whether the lightning protection grounding status can effectively resist lightning risks. When the assessment result indicates that there is a lightning risk, the lightning monitoring unit generates corresponding risk warning information and transmits the warning signal to the monitoring center through a preset communication link, and simultaneously displays the risk warning on the information display unit of the gantry crane.

[0051] It should be noted that the lightning monitoring unit does not simply detect the lightning protection grounding status, but generates risk alerts by combining environmental characteristics and assessment logic, thereby improving the accuracy and relevance of lightning risk assessment. By sending early warning signals to the monitoring center, it achieves remote synchronous notification of lightning risks, facilitating the monitoring center's overall coordination and emergency response. At the same time, it displays alerts locally on the gantry crane, allowing on-site operators to take timely avoidance measures, effectively reducing the harm of lightning weather to the gantry crane equipment and operators, and improving the safety protection level of the gantry crane under special weather conditions.

[0052] Preferably, the intelligent monitoring and early warning system for gantry crane status also includes a remote communication unit, which is configured to upload the status data of multiple gantry cranes to the monitoring center to realize centralized monitoring and management of multiple gantry cranes.

[0053] Specifically, a remote communication unit is installed in the signal processing area of ​​each gantry crane, establishing a data connection with the signal acquisition and logic processing unit of each gantry crane to collect various status data, logic judgment results, alarm information, etc. of each gantry crane in real time. The remote communication unit uploads the collected data from multiple gantry cranes to a preset monitoring center through a stable network transmission link and in accordance with a unified data transmission format and protocol. The monitoring center classifies, stores, displays, and statistically analyzes the uploaded data to form a panoramic view of the operating status of multiple gantry cranes.

[0054] It should be noted that the remote communication unit breaks the limitations of local monitoring of a single gantry crane, enabling centralized aggregation of status data from multiple gantry cranes. The centralized management mode of the monitoring center allows managers to fully grasp the operating status of all gantry cranes without having to go to the site one by one, promptly identify common problems across gantry cranes or abnormal situations of individual gantry cranes, facilitate the overall scheduling of maintenance resources, formulate maintenance plans, improve the efficiency and scientific nature of gantry crane management, and reduce management costs and troubleshooting time.

[0055] Accordingly, this embodiment also provides a method for intelligent monitoring and early warning of door operator status, including: detecting the real-time status of the door operator through several status sensors installed on key parts of the door operator, such as power status, lock status, brake status, door and window closing status, and grounding status; collecting status sensor signals, performing logical judgment and comprehensive control; and displaying the status information and alarm prompts of each monitoring point in real time based on the results of logical judgment and comprehensive control.

[0056] Specifically, firstly, based on the key operating parts of the gantry crane and safety monitoring requirements, several status sensors are deployed at corresponding locations. Each sensor continuously monitors the real-time status of the gantry crane's power connection, locking mechanism, brake, door and window closure, and grounding structure according to preset detection frequency and accuracy requirements, generating corresponding status signals. Subsequently, the signals output by all status sensors are collected through a signal acquisition link. After filtering, organizing, and analyzing the signals, logical judgments are executed according to the safety standards and preset logic rules of the gantry crane operation to determine whether the status of each monitoring point is normal and generate corresponding comprehensive control commands. Finally, the logical judgment results and comprehensive control commands are transmitted to the information display equipment to intuitively display the normal or abnormal status of each monitoring point in real time. When an abnormality is detected, the corresponding alarm prompt is triggered to remind the operator to handle it in a timely manner.

[0057] It should be noted that this method ensures the comprehensiveness and timeliness of the gantry crane's real-time status information through the precise placement and continuous monitoring of sensors; the process design of signal acquisition, logic judgment, and integrated control ensures rapid processing and accurate judgment of status information, enabling the system to promptly identify anomalies; and the real-time display and alarm notification functions realize the visualization of status information and rapid notification of abnormal situations, helping operators to grasp the gantry crane's operating status in a timely manner, respond quickly to faults, effectively reduce the risk of fault escalation, ensure the safety and continuity of gantry crane operations, and improve the overall reliability of gantry crane operation.

[0058] Example 2 This embodiment provides a gate operator status intelligent monitoring and early warning system, including: multiple status sensors installed in key parts of the gate operator; a PLC unit for signal acquisition and logic processing; and a touch display terminal installed on the lower crossbeam of the gate operator.

[0059] Specifically, corresponding status sensors are installed at each critical safety location of the gantry crane (including but not limited to the main power circuit, the trolley locking device, the trolley locking device, the brake, the driver's cab doors and windows, the trolley machine room door, and the lightning protection grounding point); among them, the status sensors are used to detect the working status of the corresponding mechanism in real time (such as disconnected / closed, engaged / not engaged, closed / opened, brake held / released, etc.) and output the signal to the PLC unit.

[0060] In this embodiment, the PLC unit is used to collect, filter, logically judge and store the signals of each status sensor; the PLC unit makes a comprehensive judgment on the status of each part according to the preset logic rules (such as "an abnormal signal is issued when the power is not disconnected or the lock is not engaged") and generates unified door machine safety status data.

[0061] Specifically, the touch display terminal is connected to the PLC unit via a communication line to display the status information of each monitoring point in real time. When the system detects an abnormal state, the touch screen can alert the inspection personnel through color, icon, or audible and visual alarms. The inspection personnel only need to operate the touch screen on the ground to quickly understand the current status of all key parts of the gantry crane without having to climb to a high place.

[0062] Preferably, the system may be further expanded to include: Wind speed monitoring module: Used to automatically determine whether the gantry crane is in a safe state under strong wind conditions, and to report production safety by detecting the activation status of wind-resistant fixing devices such as trolleys and cranes.

[0063] Lightning monitoring module: Used to automatically generate risk warnings based on the lightning protection grounding status, and can generate safety reports based on the lightning protection grounding status by sending early warning signals through the monitoring center.

[0064] Remote communication module: used to upload the status data of each gantry crane to the monitoring center, so as to realize centralized monitoring and management of multiple gantry cranes.

[0065] Example 3 This embodiment is based on embodiment 2: like Figures 1-3 As shown, this embodiment provides an intelligent monitoring and early warning system for gantry crane status, including: gantry crane body 1, gantry crane mobile power supply device 2, gantry crane trolley room 3, lightning rod and lightning protection grounding monitoring unit 4, trolley ground anchor and engagement detection device 5, trolley ground anchor and engagement detection device 6, driver's cab window and switch detection unit 7, trolley rail support and engagement detection device 8, driver's cab door and switch detection unit 9, anemometer 10, trolley room door and switch detection unit 11, trolley rail clamp and engagement detection device 12, information display and human-computer interaction unit 13, lifting mechanism height absolute encoder 14, and safety brake engagement detection device 15.

[0066] Preferably, the gantry crane body 1 has a double-leg structure, with all power and signal cables laid through the inner cavity of the legs to prevent exposure and damage. The gantry crane mobile power supply device 2 serves as the overall power supply device for the gantry crane, providing power to the entire gantry crane through a ground distribution box, power cables, trolley cable reel, and slip rings. The gantry crane trolley room 3 houses the lifting mechanism and control system, with the signal acquisition and logic processing unit (PLC unit) installed inside. The top of the gantry crane trolley room 3 is equipped with a lightning rod and a lightning protection grounding monitoring unit 4, which uses online monitoring equipment to monitor the continuity and grounding resistance of the lightning protection system in real time and outputs analog signals to the PLC unit.

[0067] Preferably, the gantry crane ground anchor and engagement detection device 5 works in conjunction with the ground anchor pit to lock the gantry crane mechanism, preventing the gantry crane from being blown away by strong winds. A proximity switch detects whether the ground anchor is engaged. The trolley ground anchor and engagement detection device 6 works in conjunction with the anchor pit on the surface of the gantry crane's upper beam to lock the trolley mechanism, preventing the trolley from being blown away by strong winds. A proximity switch detects whether the trolley ground anchor is engaged. The driver's cab window and switch detection unit 7 is used to detect whether the driver's cab window is closed. The trolley rail support and engagement detection device 8 is the trolley rail support device, preventing the trolley from being blown away by strong winds. A proximity switch detects whether it is engaged.

[0068] Preferably, the driver's cab door and switch detection unit 9 is used to detect whether the driver's cab door is closed. The anemometer 10 is used to measure the wind speed. The trolley machine room door and switch detection unit 11 is used to detect whether the trolley machine room door is closed. The trolley rail clamp and engagement detection device 12 is a trolley rail clamping device to prevent the trolley from being blown away by strong winds, and its engagement is detected by a proximity switch.

[0069] It should be noted that the trolley ground anchor and engagement detection device 5, the trolley ground anchor and engagement detection device 6, the trolley rail support and engagement detection device 8, and the trolley rail clamp and engagement detection device 12 are all wind-resistant fixing devices. Each device is equipped with a proximity switch or limit switch to detect whether it is in the engaged state. The driver's cab window and switch detection unit 7, the driver's cab door and switch detection unit 9, and the trolley engine room door and switch detection unit 11 are all equipped with switch detection units to determine the closed state.

[0070] Preferably, the information display and human-machine interaction unit 13 is installed at the lower end of the gantry crane's crossbeam and is a touch screen terminal used to display system operating status information in real time and communicate with the PLC unit via an Ethernet interface; the lifting mechanism height absolute encoder 14 is used to detect the position of the lifting mechanism hook and realize hook height monitoring; the safety brake engagement detection device 15 is used to detect the brake engagement status and ensure operational safety.

[0071] like Figure 4 As shown, the power supply section of this system includes a main power supply Q1, auxiliary power supplies Q2 and Q3, and a power module PS. The power module PS receives AC 220V input and outputs DC 24V, powering the signal acquisition and logic processing unit, the analog signal acquisition unit (extended), and the touch display terminal. The power supply is drawn from the lighting and auxiliary circuits, specifically from the upper end of the main circuit breaker Q1, and can monitor the status of the main circuit breaker Q1 and the main contactor K01 of the gantry crane.

[0072] like Figure 5 As shown, the signal acquisition and logic processing unit (PLC unit) acquires the following objects: Electrical components: Main circuit breaker is engaged, main contactor K01 is in the correct state; Mechanical components: Safety brake, trolley rail clamp engaged, trolley rail support engaged, trolley and trolley ground anchor engaged status; Safety protection features: Detection of driver's cab door, window, and engine room door closure; Lifting height signal; Environmental components: wind speed signal, lightning protection grounding resistance signal.

[0073] like Figure 6 As shown, the analog signal acquisition unit detects whether the height of the main hoisting mechanism is close to the upper limit position by inputting data from the height encoder and calibrating the height; it detects the wind speed by using an anemometer and inputs analog data to the PLC unit for display on the touch screen terminal; and it detects the grounding resistance value by using a lightning protection grounding detection device and inputs analog data to the PLC unit for display on the touch screen terminal.

[0074] In this embodiment, the PLC unit communicates with the touch display terminal via an Ethernet interface (ETH) to display various monitoring signals in real time on the terminal interface. During system operation, if any abnormal signal is detected (such as lightning protection grounding failure, doors and windows not closed, anchoring devices not engaged, wind speed exceeding limits, etc.), the touch display terminal will automatically alarm and display the fault location information, reminding operators to complete protective preparations before severe weather.

[0075] It should be noted that after the system is powered on, the PLC unit performs a self-test on all input signals to confirm that all switches and status sensors are working properly. Operators can view an overview of the gantry crane's operating status on the touchscreen terminal.

[0076] The above description is merely a preferred embodiment of the present invention. It should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the concept described herein through the above teachings or related technologies or knowledge. Modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

[0077] It should be noted that, for the sake of simplicity, the foregoing method embodiments are described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, as some steps may be performed in other orders or simultaneously according to this application. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions and modules involved are not necessarily essential to this application.

[0078] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set", "install", and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a wired connection or a wireless connection.

Claims

1. A gate operator status intelligent monitoring and early warning system, characterized in that, include: Several status sensors are installed at key parts of the door operator to detect the real-time status of the door operator; the real-time status of the door operator includes power status, lock status, brake status, door and window closure status, and grounding status; The signal acquisition and logic processing unit is configured to acquire status sensor signals and perform logical judgments and integrated control. The information display and human-computer interaction unit is configured to display the status information and alarm prompts of each monitoring point in real time based on the logical judgment and comprehensive control results of the signal acquisition and logic processing unit.

2. The intelligent monitoring and early warning system for gantry crane status according to claim 1, characterized in that, The signal acquisition and logic processing unit is installed inside the gantry crane machine room; the top of the gantry crane machine room is equipped with a lightning rod and a lightning protection grounding monitoring device, which is configured to detect the on / off state of the lightning protection system and the grounding resistance in real time, and output signals to the signal acquisition and logic processing unit.

3. The intelligent monitoring and early warning system for gantry crane status according to claim 2, characterized in that, The gantry crane trolley room is also equipped with a lifting mechanism and control system; the lifting mechanism is equipped with a height detection device, which is configured to detect the position of the lifting mechanism hook and realize hook height monitoring; the gantry crane's safety brake is equipped with a brake detection device, which is configured to detect the brake action status.

4. The intelligent monitoring and early warning system for gantry crane status according to claim 1, characterized in that, The signal acquisition and logic processing unit acquires signals from the electrical, mechanical, safety protection, and environmental components. The electrical signals include the main circuit breaker's engaged state and the main contactor's state. The mechanical signals include the safety brake's holding state and the wind-resistant fixing device's engaged state. The safety protection signals include the driver's cab door, window, and engine room door's closed state signals and the lifting height signal. The environmental signals include wind speed signals and lightning protection grounding resistance signals.

5. The intelligent monitoring and early warning system for gantry crane status according to claim 1, characterized in that, The information display and human-computer interaction unit is a touch screen terminal, installed at the lower beam of the gantry crane, and communicates with the signal acquisition and logic processing unit via an Ethernet interface.

6. The intelligent monitoring and early warning system for gantry crane status according to claim 1, characterized in that, It also includes a wind speed monitoring unit, which is configured to detect the wind speed signal of the environment where the gantry crane is located and to detect the activation status of the wind-resistant fixing device.

7. The intelligent monitoring and early warning system for gantry crane status according to claim 6, characterized in that, The wind-resistant fixing device includes a trolley ground anchor, a trolley ground anchor, a trolley rail support, and a trolley rail clamp. Each wind-resistant fixing device is equipped with a detection switch to detect whether it is in the activated state.

8. The intelligent monitoring and early warning system for gantry crane status according to claim 1, characterized in that, It also includes a lightning monitoring unit, which is configured to generate risk alerts based on the lightning protection grounding status of the gantry crane and can send early warning signals through the monitoring center.

9. The intelligent monitoring and early warning system for gantry crane status according to claim 1, characterized in that, It also includes a remote communication unit, which is configured to upload the status data of multiple gantry cranes to the monitoring center to realize centralized monitoring and management of multiple gantry cranes.

10. A method for intelligent monitoring and early warning of gantry crane status, characterized in that, include: The real-time status of the door operator is detected by several status sensors installed in key parts of the door operator, including power status, lock status, brake status, door and window closing status, and grounding status. Collects status sensor signals and performs logical judgments and integrated control; Based on the logical judgment and comprehensive control results, the status information and alarm prompts of each monitoring point are displayed in real time.

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