Simulation operation teaching system for gantry crane

Abstract

The invention relates to a simulation operation teaching system for an overhead and gantry crane in the field of hoisting driving training equipment, and the system comprises a console which is used for receiving an operation instruction of an operator; the motion feedback mechanism is used for providing multi-degree-of-freedom real-time force feedback for the console according to the mechanical dynamics of the virtual scene; the virtual scene generation module is in communication connection with the console and the motion feedback mechanism, and is used for generating and driving a three-dimensional virtual scene of the gantry crane linked with the operation instruction; the data acquisition module is used for acquiring action information of an operator and operation parameters in a virtual scene in real time; the comprehensive evaluation module is connected with the data acquisition module and is used for analyzing and quantitatively scoring the acquired data and generating an operation evaluation report; the simulation operation teaching system can realize specialized training with high efficiency, low cost and high safety.

Description

Technical Field

[0001] This invention relates to the field of crane operation training equipment, and in particular to a bridge crane simulation operation teaching system. Background Technology

[0002] Gantry cranes, as important material handling equipment, are widely used in industrial plants, railway freight yards, ports, and other places. Their operation is characterized by high professionalism, high safety risks, and complex operating scenarios. Operators must undergo systematic and standardized professional training to master equipment operation skills and safety procedures before they can work on the job. Currently, the training of gantry crane operators mainly relies on two modes: one is on-site operation training, which is training on a real crane. Although this method has a high degree of realism, it has problems such as high training costs, high safety risks, limited training scenarios, and low training efficiency; the other is computer-based two-dimensional simulation training software. Although this method reduces costs and risks to a certain extent, it has poor scene immersion, weak interactivity, and lacks realistic operating feel and mechanical feedback, and cannot effectively train operators' spatial perception, coordination, and emergency response capabilities. In recent years, virtual reality (VR) and simulation technologies have begun to be applied in the field of industrial training. However, after searching and analyzing existing technologies, it was found that current VR training systems still have the following significant defects when adapted to specific equipment such as bridge cranes: distorted equipment motion models, most systems only provide visual and auditory feedback, incomplete operational feedback mechanisms, existing systems often focus on basic operations, and safety procedure training modules are missing; and there is a lack of objective and quantitative professional evaluation systems. For example, Chinese patent CN113920242B discloses an intelligent tower crane teaching system based on virtual reality of driving scenarios, but it relies on external physical models and camera feedback, making the system complex, and the model does not match the motion mechanism of bridge cranes. Summary of the Invention

[0003] To overcome the shortcomings in the background technology and solve the technical problems existing in the current training methods, such as mismatched motion models, unrealistic operation feedback, lack of safety training, and incomplete evaluation system, this invention discloses a bridge crane simulation operation teaching system, which can achieve professional training with high efficiency, low cost, and high safety.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A simulated operation teaching system for gantry cranes includes: a control console for receiving operation commands from operators, the control console comprising a driver's seat, a main control panel, a handle group, and foot pedals; a motion feedback mechanism connected to the control console for providing multi-degree-of-freedom real-time force feedback to the control console based on the dynamic mechanics of the virtual scene; a virtual scene generation module communicatively connected to the control console and the motion feedback mechanism for generating and driving a three-dimensional virtual scene of the gantry crane that is linked to the operation commands; a data acquisition module for real-time acquisition of operator motion information and operating parameters in the virtual scene; and a comprehensive evaluation module signal-connected to the data acquisition module for analyzing, quantifying, and scoring the acquired data and generating an operation evaluation report.

[0005] Furthermore, a support platform is provided in front of the driver's seat of the control panel, the main control panel is installed on the front end of the support platform, the foot pedal is located below the support platform, the handle group is located on the side of the support platform and includes at least two independent multi-degree-of-freedom control handles, and the control handles are integrated with vibration motors to provide tactile feedback when specific events are triggered in the virtual scene.

[0006] Furthermore, the motion feedback mechanism includes a base located below the driver's seat. Between the driver's seat and the base, there are multiple electrically operated telescopic cylinders that are driven and positioned by a drive assembly. The drive assembly is used to drive the electrically operated telescopic cylinders to move according to the instructions of the virtual scene generation module, thereby applying force feedback to the driver's seat. The two ends of the electrically operated telescopic cylinders are respectively hinged to the upper surface of the base and the bottom surface of the driver's seat via universal hinges. Force sensors for monitoring force data are installed at the universal hinges.

[0007] Furthermore, the virtual scene generation module includes: a scene modeling unit for constructing a high-precision 3D model of the gantry crane and its operating environment; a physics engine unit for simulating in real time the mechanical characteristics of wire rope tension changes, load swing, inertia, and collisions during the operation of the gantry crane; and a rendering unit for rendering and outputting the 3D model and physics simulation results in real time.

[0008] Furthermore, the data acquisition module includes: a motion capture unit, employing optical motion capture equipment, for capturing the limb movement trajectory of the operator; a sensor group, including a displacement sensor and a pressure sensor disposed on the handle group, and a pressure sensor disposed on the foot pedal; and a data storage unit, for storing the data acquired by the motion capture unit and the sensor group.

[0009] Furthermore, the comprehensive evaluation module includes: a data analysis unit for processing the collected data and extracting operational feature indicators; a scoring unit with a built-in pre-set scoring rule library for quantitative scoring based on the operational feature indicators; and a report generation unit for integrating the scoring results and process data to generate a visual evaluation report.

[0010] Furthermore, the virtual scene generation module integrates safety procedure training logic, which is used to simulate limit protection and anti-collision area warning in the three-dimensional virtual scene, and trigger at least one alarm mechanism including visual warning, force feedback or tactile feedback when operation is violated.

[0011] By employing the technical solution described above, the present invention has the following beneficial effects: The bridge crane simulation operation teaching system disclosed in this invention conducts training entirely in a virtual environment, eliminating the need for a real crane. This saves significant costs in terms of equipment wear and tear, energy consumption, and site occupancy. It also completely eliminates the risk of personnel injury and equipment damage during on-site operation training. Furthermore, it allows for rapid switching between different crane models, lifting equipment types, operating scenarios, and various weather conditions, lighting conditions, and even malfunctions, greatly enriching the training content and enhancing its relevance and coverage.

[0012] The bridge crane simulation operation teaching system disclosed in this invention realizes a complete training loop from "command input - scenario simulation - feedback output - data acquisition - intelligent evaluation - report feedback". Trainees can practice repeatedly without risk and quickly identify their shortcomings through objective evaluation reports, achieving targeted and efficient skill improvement. Moreover, by using a virtual scene generation module to realistically reproduce the unique motion mode and mechanical characteristics of bridge cranes, combined with a multi-degree-of-freedom force feedback platform and handle vibration, it provides trainees with an immersive operation experience that integrates multiple senses, including vision, force, and touch, effectively promoting skill internalization and the formation of "muscle memory". In addition, it can also deeply embed safe operating procedures, such as limit switches, anti-collision, anti-sway, and emergency braking, into the virtual scene logic and feedback mechanism. Once a trainee violates the operation, the system immediately intervenes and reminds them through visual warnings, force feedback resistance, and vibration, thereby firmly establishing a safe operating awareness in the simulation training. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of an embodiment of the present invention; In the diagram: 1. Support platform; 2. Main control panel; 3. Handle assembly; 4. Foot pedal; 5. Base; 6. Electric telescopic cylinder; 7. Force sensor; 8. Drive assembly; 9. Scene modeling unit; 10. Physics engine unit; 11. Rendering unit; 12. Motion capture unit; 13. Sensor assembly; 14. Data storage unit; 15. Data analysis unit; 16. Driver's seat; 17. Report generation unit. Detailed Implementation

[0014] The technical solution of the present invention will be described below with reference to the accompanying drawings of the embodiments of the present invention. In the description, it should be understood that if there are terms such as "upper", "lower", "front", "rear", "left", "right" indicating the orientation or positional relationship, they are only corresponding to the accompanying drawings of the present invention for the convenience of describing the present invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation.

[0015] Combined with appendix Figure 1 The bridge crane simulation operation teaching system includes a control panel, a motion feedback mechanism, a virtual scene generation module, a data acquisition module, and a comprehensive evaluation module. The control console is used to receive operating instructions from the operator. The control console includes a driver's seat 16, a main control panel 2, a handle group 3, and a foot pedal 4. The control console is the human-machine interface terminal for the operator to input instructions. The main control panel 2 is equipped with a touch screen to display virtual scenes, equipment status parameters, such as the height of the spreader, the load weight, the position of the trolley and the crane, and operating instructions. As needed, a support platform 1 is provided in front of the driver's seat 16 of the control console. The main control panel 2 is installed at the front end of the support platform 1. The foot pedal 4 is located below the support platform 1 and simulates an emergency brake pedal. It is equipped with a high-precision pressure sensor to detect the stepping force and trigger the braking action in the virtual scene. The handle group 3 is located on the side of the support platform 1 and includes at least two independent multi-degree-of-freedom control handles, which respectively simulate the control of the crane's trolley travel, crane translation, and spreader lifting. The control handles are integrated with vibration motors to provide tactile warnings when the spreader contacts obstacles or reaches the limit. A motion feedback mechanism, connected to the control panel, provides real-time force feedback with multiple degrees of freedom to the control panel based on the dynamic mechanics of the virtual scene. As needed, the motion feedback mechanism includes a base 5 located below the driver's seat 16. The base 5 is fixed to the ground, providing stable support for the entire mechanism. A shock-absorbing mechanism is provided at the bottom. Multiple electrically operated telescopic cylinders 6, preferably four, are driven by a drive assembly 8 for telescopic positioning between the driver's seat 16 and the base 5. The drive assembly 8 drives the electrically operated telescopic cylinders 6 to move according to the instructions of the virtual scene generation module, thereby applying force feedback to the driver's seat 16. The feedback mechanism specifically utilizes the servo motor and ball screw drive assembly 8 to link with each telescopic cylinder, receiving the mechanical model calculation results from the virtual scene, and precisely driving the telescopic cylinders to extend and retract, thereby applying forces of corresponding direction and magnitude to the control panel, specifically the driver's seat 16, to simulate the load feeling, inertial force and collision reaction force during crane operation. The two ends of the electric telescopic cylinder 6 are respectively hinged to the upper surface of the base 5 and the bottom surface of the driver's seat 16 through universal hinges, forming a support structure that can simulate multi-degree-of-freedom movements such as pitch, roll, and lifting. Force sensors 7 for monitoring force data are installed at the universal hinges. The virtual scene generation module is the core processing and rendering hub of the system. It communicates with the control console and motion feedback mechanism to generate and drive a 3D virtual scene of the gantry crane that is linked to operating commands. Depending on the requirements, the virtual scene generation module includes: a scene modeling unit 9, used to construct a high-precision 3D model of the gantry crane and its operating environment, building a high-precision 3D model library containing various components of the gantry crane such as rails, trolley structure, trolley, and various lifting devices, as well as various typical operating environments such as factories, ports, and railway freight yards. It supports importing external 3D models to expand training scenes; and a physics engine unit 10, which uses a high-performance multi-threaded physics engine to calculate and simulate the complex mechanics of crane operation in real time. The system includes phenomena such as the dynamic changes in the elasticity and tension of the wire rope, the swinging and suppression of the suspended load, the inertial effects during the start-up and braking of the trolley and the carriage, and precise collision detection and response; and a rendering unit 11, which is used to render and output the 3D model and physical simulation results in real time. Based on the graphics workstation, the 3D model and physical calculation results are rendered realistically in real time and output as an immersive visual scene through high-definition display devices such as VR headsets or multi-screen displays; in addition, the virtual scene generation module integrates safety procedure training logic, which is used to simulate limit protection and anti-collision area warning in the 3D virtual scene, and trigger at least one alarm mechanism including visual warning, force feedback or tactile feedback when the operation is violated. The data acquisition module is used to collect the operator's motion information and the operating parameters in the virtual scene in real time. The data acquisition module includes: a motion capture unit 12, which uses optical motion capture equipment to capture the operator's limb movement trajectory, specifically using an array of infrared optical motion capture cameras arranged around the control panel to accurately record the spatial movement trajectory of the operator's hands and arms; a sensor group 13, including displacement sensors and pressure sensors set on the handle group 3, and pressure sensors set on the foot pedal 4, used to collect the amplitude, speed and force of the operation commands; and a data storage unit 14, used to store the data collected by the motion capture unit 12 and the sensor group 13, using a high-speed solid-state drive, and storing all motion data and virtual scene state parameters in real time through a wired and wireless hybrid communication network to form a complete training data stream. The comprehensive evaluation module, connected to the data acquisition module, is used to analyze, quantify, and score the acquired data, and generate an operation evaluation report. The comprehensive evaluation module includes: a data analysis unit 15, which processes the acquired data and extracts operational characteristic indicators, such as operational stability (velocity curve variance), positioning accuracy (deviation from the target point), coordination (multi-agency linkage timing), and safety procedure trigger records; a scoring unit, which has a built-in pre-set scoring rule library for quantitative scoring based on operational characteristic indicators. Specifically, it can incorporate an expert scoring model, comparing the extracted characteristic indicators with preset standardized operation standards to automatically quantify scores from multiple dimensions such as operational skills, efficiency, and safety; and a report generation unit 17, which integrates the scoring results with process data to generate a visual evaluation report. This unit integrates the scoring results with detailed process data (such as operation trajectory playback and key event screenshots) to automatically generate a personalized evaluation report with both text and graphics, indicating operational advantages and areas for improvement.

[0016] Implementing the bridge crane simulation operation teaching system described in this invention: 1. Hardware system setup: The control panel is designed as an ergonomic cockpit structure. The touch screen on the main control panel 2 is installed with quick-release buckles for easy maintenance and upgrades. The two handles are covered with anti-slip rubber, and the internal circuit board integrates a vibration motor (either an ERM or LRA micro motor). The foot pedal 4 uses an aluminum alloy frame and a polyurethane elastic tread surface, and the pressure sensor (such as a strain gauge) underneath it has a range of 0-500N. The base 5 of the motion feedback mechanism is fixed to the ground by anchor bolts. The four electric telescopic cylinders 6 are arranged in a rectangle and are driven by servo motors (such as Panasonic MINAS A6 series) to drive precision ball screws (such as HIWIN brand) to achieve millimeter-level displacement control. The force sensor 7 at each ball joint (such as a six-dimensional force and torque sensor) feeds the force data back to the control system in real time.

[0017] 2. Software system configuration: The virtual scene generation module runs on a high-performance graphics workstation (such as one equipped with an NVIDIA RTX series graphics card). The scene modeling unit 9 uses Unity 3D or Unreal Engine to build a model library. The physics engine unit 10 can use NVIDIA PhysX or Bullet Physics and write dedicated plugins to simulate wire rope dynamics and crane multibody dynamics. The motion capture unit 12 of the data acquisition module uses an OptiTrack or similar infrared camera system (at least 3), with a sampling frequency of not less than 120Hz; all sensor data is aggregated to the SSD of the data storage unit 14 via USB or Ethernet; The software for the comprehensive evaluation module runs on the same workstation or another analysis server. The data analysis unit 15 uses algorithms written in Python or C# to process the data stream. The scoring unit has a built-in scoring rule library that can be configured, for example: "If the positioning deviation of the lifting device exceeds ±10cm, deduct 5 points"; "If the emergency braking response time exceeds 2 seconds, deduct 10 points". The report generation unit 17 uses reporting tools (such as JasperReports) to automatically generate evaluation reports in PDF format.

[0018] 3. Workflow: After entering the simulation system, trainees first select a training scenario (such as "port container loading and unloading") and operate it using the handle and foot pedal 4, for example, pushing the right handle to control the trolley to move forward; The virtual scene generation module calculates the movement of the trolley and the swing of the load in real time, and outputs the visual scene to the display. At the same time, it sends the calculated "trolley starting inertial force" data to the motion feedback mechanism. The drive component 8 of the motion feedback mechanism drives the corresponding electric telescopic cylinder 6 to move, so that the control panel generates a simulated inertial force backward tilting force. The data acquisition module records the trainee's operation instructions, movement trajectory, and scene status throughout the entire training task. After the training task is completed, the comprehensive evaluation module automatically analyzes the data and gives evaluations such as "The overall score for this operation is 85 points. The control of the spreader swing needs to be improved. The safety procedures were well followed," along with detailed data charts.

[0019] 4. Example of safety training: When the trainee operates the hoist near the end of the track in the virtual scene, the physics engine unit 10 detects that the position is about to exceed the limit. The rendering unit 11 immediately displays a flashing red warning area on the screen and issues a voice warning. At the same time, the motion feedback mechanism causes the control panel to generate a gradually increasing reverse force toward the center of the track, simulating physical limit blocking. The handle also vibrates strongly. If the trainee does not correct the operation and causes a virtual "collision", the system will record a safety violation and deduct points in the evaluation report.

[0020] The system equipment can be connected to the enterprise intranet or cloud training management platform. Instructors can monitor the real-time training status of multiple trainee terminals through the instructor station, remotely issue training tasks, set faults (such as simulated motor overheating, wire rope slippage), and view the historical evaluation reports of all trainees online, and conduct group management and training effect statistical analysis.

[0021] The parts of this invention not described in detail are prior art. It will be apparent to those skilled in the art that this invention is not limited to the details of the above exemplary embodiments, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the above embodiments should be regarded as exemplary and non-limiting in all respects. The scope of this invention is defined by the appended claims rather than the foregoing description. Therefore, it is intended to include all changes that fall within the meaning and scope of the equivalents of the claims within this invention, and no reference numerals in the claims should be regarded as limiting the content of the claims.

Claims

1. A simulated operation teaching system for bridge gantry cranes, Its characteristics include: A control panel is used to receive operating instructions from the operator. The control panel includes a driver's seat, a main control panel, a handle group, and foot pedals. A motion feedback mechanism, connected to the control panel, is used to provide real-time force feedback with multiple degrees of freedom to the control panel based on the mechanical dynamics of the virtual scene. The virtual scene generation module is communicatively connected to the control panel and motion feedback mechanism, and is used to generate and drive a three-dimensional virtual scene of the bridge crane that is linked with the operation commands. The data acquisition module is used to collect the operator's action information and the operating parameters in the virtual scene in real time; The comprehensive evaluation module is connected to the data acquisition module and is used to analyze, quantify, score, and generate an operation evaluation report from the acquired data.

2. The bridge crane simulation operation teaching system according to claim 1, characterized in that: A support platform is provided in front of the driver's seat. The main control panel is installed on the front end of the support platform. The foot pedal is located below the support platform. The handle assembly is located on the side of the support platform and includes at least two independent multi-degree-of-freedom control handles. The control handles are equipped with vibration motors to provide tactile feedback when specific events are triggered in the virtual scene.

3. The bridge crane simulation operation teaching system according to claim 1, characterized in that: The motion feedback mechanism includes a base located below the driver's seat. Between the driver's seat and the base are multiple electrically operated telescopic cylinders that are driven and positioned by a drive assembly. The drive assembly is used to drive the electrically operated telescopic cylinders to move according to the instructions of the virtual scene generation module, thereby applying force feedback to the driver's seat. The two ends of the electrically operated telescopic cylinders are respectively hinged to the upper surface of the base and the bottom surface of the driver's seat via universal hinges. Force sensors for monitoring force data are installed at the universal hinges.

4. The bridge crane simulation operation teaching system according to claim 1, characterized in that: The virtual scene generation module includes: a scene modeling unit for constructing a high-precision 3D model of the gantry crane and its operating environment; a physics engine unit for simulating in real time the mechanical characteristics of wire rope tension changes, load swing, inertia, and collisions during the operation of the gantry crane; and a rendering unit for rendering and outputting the 3D model and physics simulation results in real time.

5. The bridge crane simulation operation teaching system according to claim 1, characterized in that: The data acquisition module includes: a motion capture unit, employing optical motion capture equipment, for capturing the limb movement trajectory of the operator; a sensor group, including a displacement sensor and a pressure sensor mounted on the handle group, and a pressure sensor mounted on the foot pedal; and a data storage unit, for storing the data acquired by the motion capture unit and the sensor group.

6. The bridge crane simulation operation teaching system according to claim 1, characterized in that: The comprehensive evaluation module includes: a data analysis unit for processing the collected data and extracting operational feature indicators; a scoring unit with a built-in pre-set scoring rule library for quantitative scoring based on the operational feature indicators; and a report generation unit for integrating the scoring results and process data to generate a visual evaluation report.

7. The bridge crane simulation operation teaching system according to claim 4, characterized in that: The virtual scene generation module integrates safety procedure training logic, which is used to simulate limit protection and anti-collision area warning in the three-dimensional virtual scene, and trigger at least one alarm mechanism including visual warning, force feedback or tactile feedback when the operation is violated.

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