Tower crane rotation and stroke safety linkage control system

Abstract

The invention discloses a safety linkage control system for rotation and stroke of a tower crane, which belongs to the technical field of safety control of engineering machinery and is used for detecting the rotation angle of a big arm and the running amplitude of a lifting hook trolley in real time based on two-parameter linkage logic judgment of the rotation angle and the amplitude of the trolley. Dynamic and accurate protection of any preset specified fan-shaped dangerous area in a tower crane operation plane is achieved, qualitative change from single-point limiting to dynamic area intelligent protection is achieved, the future movement track of a lifting hook is predicted by introducing double-track speed perspectiveness, graded early warning, speed limiting and pre-braking are carried out before a safety boundary is impacted, and the safety boundary is protected. The safety logic of the system is improved from boundary collision detection to the level of dynamic trajectory prediction and active guidance, so that equipment can stably decelerate and stop in front of a dangerous boundary, sudden stop impact in an original threshold triggering mode is avoided, the mechanical structure is protected, the operation comfort is improved, and the service life of the equipment is prolonged.

Description

Technical Field

[0001] This invention relates to the field of safety control technology for engineering machinery, and more specifically, to a tower crane rotation and travel safety linkage control system. Background Technology

[0002] Tower cranes are widely used in construction. Due to their large operating range and long boom, they are prone to many safety risks in actual operation. Especially when working near high-rise building complexes, high-voltage lines, and existing buildings, the rotation of the tower crane boom and the luffing motion of the hook trolley may cause the hook and load to enter specific dangerous areas (such as high-voltage line corridors, protected building spaces, etc.). Once a collision or intrusion occurs, it will cause serious safety accidents.

[0003] Currently, tower cranes are typically equipped with single-dimensional safety devices such as limit switches and torque limiters. For example, torque limiters mainly prevent overload, while amplitude limiters only restrict the start and end points of the trolley's physical travel. However, these devices cannot solve a dynamic safety problem: when the tower crane boom is at a certain azimuth angle, even if the trolley is within the allowed physical travel, it may enter a fan-shaped danger zone.

[0004] Therefore, based on the above-mentioned technical problems, a tower crane slewing and travel safety linkage control system is proposed. Summary of the Invention

[0005] The purpose of this invention is to address practical deficiencies. It provides a tower crane slewing and stroke safety linkage control system, which, through two core innovations—"dual-parameter linkage" and "proactive prediction"—builds a precise, proactive, smooth, and reliable intelligent safety protection system. This effectively solves the dynamic area safety problem of tower cranes operating in complex environments, significantly improving the overall safety level and operational intelligence.

[0006] The objective of this invention can be achieved through the following technical solution: a tower crane rotation and stroke safety linkage control system, comprising a dual-track detection module, a motion state forward prediction module, a dual-track logic linkage judgment module, and a core control unit; The dual-track detection module is used to collect the current position data and current speed data of the tower crane in real time. The current position data includes the slewing angle value α and the trolley amplitude value l, and the current speed data includes the slewing angular velocity ω and the trolley linear velocity v. The data are sent together to the motion state forward prediction module and the dual-track logic linkage judgment module. The motion state forward prediction module receives the current position data and current speed data of the tower crane, and predicts the future motion trajectory of the hook based on the current position data and current speed data through a kinematic model, and sends it to the linkage judgment and execution module; The dual-rail logic linkage judgment module receives the current position data and future movement trajectory of the tower crane hook, determines whether the current hook position point simultaneously meets the preset dangerous angle condition and dangerous amplitude condition based on the current position data, and generates a safety braking signal when it is satisfied; Based on the future movement trajectory, it is judged whether there are hook position points that simultaneously meet the preset dangerous angle condition and dangerous amplitude condition within a preset future time period. When it is satisfied, the position points that meet the preset dangerous angle condition and dangerous amplitude condition are obtained, the dangerous prediction time T is determined based on the time corresponding to the position points, and multi-level intervention signals are generated according to the dangerous prediction time T. The safety braking signal and the multi-level intervention signals are jointly sent to the core control unit; The core control module receives the safety braking signal and the multi-level intervention signals, triggers the operation instructions corresponding to the signals, and performs safety operations based on the operation instructions.

[0007] Furthermore, the dual-rail detection module further includes an angle detection sub-module, an amplitude detection sub-module, and a speed detection sub-module; Among them, the angle detection sub-module is configured as an absolute encoder coaxially installed on the central axis of the tower crane slewing bearing, and is used to continuously measure the slewing angle value of the boom relative to the reference point; The amplitude detection sub-module is configured as a rope-pull displacement sensor installed at the root of the boom track, and is used to continuously measure the radial running distance of the hook trolley relative to the root of the boom; The speed detection sub-module directly calculates the real-time angular velocity by differentiating the pulse signal of the absolute encoder through a PLC high-speed counter, and calculates the linear velocity from the signal change rate of the rope-pull displacement sensor.

[0008] Furthermore, the process of obtaining the future movement trajectory specifically includes: The motion state forward-looking prediction module pre-stores a future movement trajectory model of the hook constructed in the polar coordinate system, inputs the slewing angle α, slewing angular velocity ω, trolley amplitude l, and trolley linear velocity v into the future movement trajectory model, and outputs the future movement trajectory of the hook within a preset future time period; Among them, the future movement trajectory model is a uniform motion model.

[0009] Furthermore, the preset dangerous angle condition is α(t) ∈ [A1, A2], and the dangerous amplitude condition is l(t) ≥ L.

[0010] Furthermore, the specific process of generating multi-level execution trigger signals according to the dangerous prediction time T includes: The dual-rail logic linkage judgment module pre-stores preset multi-level critical time thresholds T1, T2, T3, and T1 > T2 > T3 > 0; When the dangerous prediction time T satisfies: T2 < T ≤ T1, a first-level warning signal is generated; When the danger prediction time T satisfies: T3 < T ≤ T2, a secondary speed limit signal is generated; When the danger prediction time T satisfies: 0 < T ≤ T3, a tertiary pre-braking signal is generated.

[0011] Furthermore, the specific operation process of the core control module includes: When a safety braking signal is received, a braking instruction is triggered to lock the forward (in the direction of increasing amplitude) driving circuit of the trolley, and only allows the trolley to run backward (in the direction of decreasing amplitude). The braking is automatically released after exiting the danger area; When a primary warning signal is received, a warning prompt instruction is triggered to display a warning message through the human-machine interaction unit and / or trigger a prompt audible and visual alarm; When a secondary speed limit signal is received, a speed limit instruction is triggered to control the driving device of the hook trolley to send a speed limit instruction to limit the maximum allowable speed to a preset value; When a tertiary pre-braking signal is received, a pre-braking instruction is triggered to control the driving device of the hook trolley to send a deceleration ramp instruction, so that the hook trolley smoothly decelerates at a preset deceleration.

[0012] Among them, the present invention also proposes a safety interlock control method for tower crane slewing and travel, including the following steps: S1. Real-time collection of tower crane data: Real-time collect the current position data and current speed data of the tower crane. The current position data includes the slewing angle value α and the trolley amplitude value l, and the current speed data includes the slewing angular velocity ω and the trolley linear velocity v; S2. Prospective prediction of the tower crane motion state: Predict the future motion trajectory of the hook based on the current position data and current speed data; S3. Dual-rail interlock judgment: S31. Based on the current position data, determine whether the current hook position point simultaneously satisfies the preset dangerous angle condition and dangerous amplitude condition. When satisfied, a safety braking signal is generated; S32. Based on the future motion trajectory, judge whether there is a hook position point that simultaneously satisfies the preset dangerous angle condition and dangerous amplitude condition within a preset future time period. When satisfied, obtain the position point that satisfies the preset dangerous angle condition and dangerous amplitude condition; S33. Determine the danger prediction time based on the time corresponding to the position point, and generate multi-level intervention signals according to the danger prediction time; S4. Control execution: Respond to the safety braking signal and multi-level intervention signals, trigger the operation instructions corresponding to the signals, and perform safety operations based on the operation instructions.

[0013] Compared with the prior art, the advantages of the present invention are: This invention achieves dynamic and precise protection of any pre-defined, designated sector-shaped danger zone within the tower crane's working plane by real-time detection of the boom slewing angle and the hook trolley's travel radius. This represents a qualitative leap from "single-point limiting" to "dynamic area intelligent protection." Furthermore, by introducing dual-track speed to proactively predict the hook's future trajectory, it provides graded warnings, speed limits, and pre-braking before impacting the safety boundary. This elevates the system's safety logic from "boundary collision detection" to "dynamic trajectory prediction and active guidance," significantly enhancing the system's intelligence and the smoothness of human-machine collaborative operation.

[0014] The hierarchical logic of proactive intervention is quantitatively defined, and the time for hazard prediction is used as the sole basis for hierarchical decision-making. The hierarchical early warning mechanism provides operators with a clear sense of hazard trends and sufficient response time, which enables the equipment to decelerate and stop smoothly before the danger boundary, avoiding the sudden stop impact of the original "threshold trigger" mode, protecting the mechanical structure, and improving operating comfort and equipment life. Attached Figure Description

[0015] Figure 1 This is a system principle block diagram of the present invention; Figure 2 This is a flowchart of the method of the present invention. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0017] Example 1: Addressing the core deficiencies of tower crane safety protection devices, such as "one-dimensional, static, and passive response," the following technical solution is proposed: This invention discloses a tower crane slewing and travel safety linkage control system. Please refer to [link / reference]. Figures 1-2 It includes a dual-track detection module, a motion state forward prediction module, a dual-track logic linkage judgment module, and a core control unit; The dual-track detection module is used to collect the current position data and current speed data of the tower crane in real time. The current position data includes the slewing angle value α and the trolley amplitude value l, and the current speed data includes the slewing angular velocity ω and the trolley linear velocity v. The data are sent together to the motion state forward prediction module and the dual-track logic linkage judgment module. The dual-track detection module includes an angle detection submodule, an amplitude detection submodule, and a speed detection submodule. Among them, the angle detection sub-module is configured as an absolute encoder coaxially installed on the central axis of the tower crane's slewing bearing, and is used to continuously measure the slewing angle value of the jib relative to the reference point; The amplitude detection sub-module is configured as a rope-pull displacement sensor installed at the root track of the jib, and is used to continuously measure the radial running distance of the hook trolley relative to the root of the jib; The speed detection sub-module directly calculates the real-time angular velocity by differentiating from the pulse signal of the absolute encoder through the PLC high-speed counter, and calculates the linear velocity from the signal change rate of the rope-pull displacement sensor.

[0018] The motion state prospective prediction module receives the current position data and current speed data of the tower crane, and predicts the future motion trajectory of the hook through the kinematic model based on the current position data and current speed data, and sends it to the linkage judgment and execution module; The specific process of obtaining the future motion trajectory specifically includes: The motion state prospective prediction module pre-stores a future motion trajectory model of the hook constructed in the polar coordinate system, inputs the slewing angle α, slewing angular velocity ω, trolley amplitude l, and trolley linear velocity v into the future motion trajectory model, and outputs the future motion trajectory of the hook within a preset future time period; Among them, the future motion trajectory model is a uniform motion model; The dual-track logic linkage judgment module receives the current position data and future motion trajectory of the tower crane hook, and determines whether the current hook position point simultaneously meets the preset dangerous angle condition and dangerous amplitude condition based on the current position data. When it meets, a safety braking signal is generated; Based on the future motion trajectory, it is judged whether there is a hook position point that simultaneously meets the preset dangerous angle condition and dangerous amplitude condition within a preset future time period. When it meets, the position point that meets the preset dangerous angle condition and dangerous amplitude condition is obtained, the dangerous prediction time T is determined based on the time corresponding to the position point, and a multi-level intervention signal is generated according to the dangerous prediction time T. The safety braking signal and the multi-level intervention signal are jointly sent to the core control unit; The preset dangerous angle condition is α(t) ∈ [A1, A2], the dangerous amplitude condition is l(t) ≥ L, and the dangerous angle condition and dangerous amplitude condition form "a specific amplitude at a specific azimuth angle", thus constituting a fan-shaped dangerous area; The specific process of generating a multi-level execution trigger signal according to the dangerous prediction time T includes: The dual-track logic linkage judgment module pre-stores preset multi-level critical time thresholds T1, T2, T3, and T1 > T2 > T3 > 0; When the dangerous prediction time T satisfies: T2 < T ≤ T1, a first-level warning signal is generated; When the danger prediction time T satisfies: T3 < T ≤ T2, a secondary speed limit signal is generated; When the danger prediction time T satisfies: 0 < T ≤ T3, a tertiary pre-braking signal is generated; Through the two-parameter linkage logic judgment of the slewing angle and the trolley amplitude, the dynamic and precise protection of any designated fan-shaped danger area within the tower crane operation plane is realized for the first time; And by introducing the double-track speed to prospectively predict the future movement trajectory of the hook, it is judged whether the predicted hook position coordinate point set will fall into the preset fan-shaped danger area. When it is determined that it will fall into the preset fan-shaped danger area at a preset future time point, a hierarchical judgment is made based on the danger prediction time T, and hierarchical early warning, speed limit, and pre-braking are realized before hitting the safety boundary. This enables the equipment to smoothly decelerate and stop before the danger boundary, avoiding the sudden stop impact in the original "threshold trigger" mode, protecting the mechanical structure, and improving the operation comfort and equipment life.

[0019] The core control module receives the safety braking signal and multi-level intervention signals, triggers the operation instructions corresponding to the signals, and performs safety operations based on the operation instructions; When the safety braking signal is received, the braking instruction is triggered to lock the forward (in the direction of increasing amplitude) drive circuit of the trolley, and only allows the trolley to run backward (in the direction of decreasing amplitude), and the braking is automatically released after exiting the danger area; When the first-level early warning signal is received, the early warning prompt instruction is triggered, and the early warning information is displayed through the human-machine interaction unit and / or a prompt audible and visual alarm is triggered; When the secondary speed limit signal is received, the speed limit instruction is triggered to control the driving device of the hook trolley to send a speed limit instruction, and the maximum allowable speed is limited to a preset value; When the tertiary pre-braking signal is received, the pre-braking instruction is triggered to control the driving device of the hook trolley to send a deceleration ramp instruction, so that the hook trolley smoothly decelerates according to a preset deceleration; The hierarchical early warning mechanism provides the operator with a clear sense of the danger trend and sufficient response time (such as 3 seconds of early warning in advance and 1.5 seconds of speed limit), realizing the experience upgrade from "boundary collision" to "smooth predictive guidance".

[0020] Embodiment 2: The present invention also proposes a tower crane slewing and travel safety linkage control method. Please refer to Figure 2 , including the following steps: S1. Real-time collection of tower crane data: Real-time collect the current position data and current speed data of the tower crane. The current position data includes the slewing angle value α and the trolley amplitude value l, and the current speed data includes the slewing angular velocity ω and the trolley linear velocity v; S2. Prospective prediction of the tower crane movement state: Based on the current position data and current speed data, predict the future movement trajectory of the hook; S3, Dual-track linkage judgment: S31. Based on the current position data, determine whether the current hook position point simultaneously meets the preset danger angle condition and danger amplitude condition. If it does, generate a safety braking signal. S32. Based on the future motion trajectory, determine whether there is a hook position point that simultaneously meets the preset danger angle condition and danger amplitude condition within a preset time period. If it does, obtain the position point that meets the preset danger angle condition and danger amplitude condition. S33. Determine the hazard prediction time based on the time corresponding to the location point, and generate multi-level intervention signals based on the hazard prediction time; S4. Control Execution: Respond to safety braking signals and multi-level intervention signals, trigger corresponding operation instructions, and execute safety operations based on the operation instructions.

[0021] In summary: a dual-track detection module collects the boom rotation angle α and angular velocity ω, and the trolley amplitude l and linear velocity v in real time. A motion state forward prediction module predicts the future trajectory of the hook based on the current position and velocity using a kinematic model. The dual-track logic linkage judgment module executes dual-track logic: based on the current position, it determines whether the hook has entered a preset sector-shaped danger zone (α∈[A1, A2] and l≥L); if so, it triggers emergency braking. Based on the predicted future trajectory, it determines whether the hook is about to enter a preset sector-shaped danger zone and calculates the danger prediction time, generating a corresponding signal. The core control module responds to the signal, triggering graded pre-intervention commands (safety braking, warning, speed limit, pre-braking) and executing corresponding operations. The core objective of this invention is to trigger braking when the boom rotates to a specified angle sector and the hook trolley travels to a specified range, preventing the trolley from entering the dangerous area of ​​that sector. This achieves linkage logic control of dual position parameters, enabling precise and proactive protection of dynamic sector-shaped dangerous areas. Furthermore, it incorporates future motion trajectory judgment, providing graded warnings, speed limits, and pre-braking before impact with the safety boundary. This allows the equipment to smoothly decelerate and stop before the dangerous boundary, avoiding the sudden stop impact of the original "threshold triggering" mode, protecting the mechanical structure, improving operational comfort and equipment lifespan, and significantly enhancing the safety and intelligence level of tower crane operations.

[0022] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto; any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in the present invention, based on the technical solution and improved concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A tower crane slewing and travel safety linkage control system, characterized in that: It includes a double-track detection module, a motion state forward prediction module, a double-track logic linkage judgment module, and a core control unit; The double-track detection module is used to collect the current position data and current speed data of the tower crane in real time. The current position data includes the slewing angle value α and the trolley amplitude value l, and the current speed data includes the slewing angular velocity ω and the trolley linear velocity v, and they are jointly sent to the motion state forward prediction module and the double-track logic linkage judgment module; The motion state forward prediction module receives the current position data and current speed data of the tower crane, and predicts the future motion trajectory of the hook through a kinematic model based on the current position data and current speed data, and sends it to the linkage judgment and execution module; The double-track logic linkage judgment module receives the current position data and future motion trajectory of the tower crane hook, and determines whether the current hook position point simultaneously meets the preset dangerous angle condition and dangerous amplitude condition based on the current position data. When it is satisfied, a safety braking signal is generated; Based on the future motion trajectory, it is judged whether there are hook position points that simultaneously meet the preset dangerous angle condition and dangerous amplitude condition within a preset future time period. When it is satisfied, the position points that meet the preset dangerous angle condition and dangerous amplitude condition are obtained, the dangerous prediction time T is determined based on the time corresponding to the position points, and a multi-level intervention signal is generated according to the dangerous prediction time T. The safety braking signal and the multi-level intervention signal are jointly sent to the core control unit; The core control module receives the safety braking signal and the multi-level intervention signal, triggers the operation instructions corresponding to the signals, and performs safety operations based on the operation instructions.

2. The tower crane slewing and travel safety linkage control system according to claim 1, characterized in that: The double-track detection module further includes an angle detection sub-module, an amplitude detection sub-module, and a speed detection sub-module; Among them, the angle detection sub-module is configured as an absolute encoder coaxially installed on the central axis of the tower crane slewing bearing, and is used to continuously measure the slewing angle value of the jib relative to the reference point; The amplitude detection sub-module is configured as a rope-pull displacement sensor installed at the root track of the jib, and is used to continuously measure the radial running distance of the hook trolley relative to the root of the jib; The speed detection sub-module directly calculates the real-time angular velocity by differentiating through the PLC high-speed counter from the pulse signal of the absolute encoder, and calculates the linear velocity from the signal change rate of the rope-pull displacement sensor.

3. The tower crane slewing and travel safety linkage control system according to claim 2, characterized in that: The specific process of obtaining the future motion trajectory specifically includes: The motion state forward prediction module pre-stores a future motion trajectory model of the hook constructed in the polar coordinate system, inputs the slewing angle α, slewing angular velocity ω, trolley amplitude l, and trolley linear velocity v into the future motion trajectory model, and outputs the future motion trajectory of the hook within a preset future time period; Among them, the future motion trajectory model is a uniform motion model.

4. The tower crane slewing and travel safety linkage control system according to claim 3, characterized in that: The preset dangerous angle condition is α(t) ∈ [A1, A2], and the dangerous amplitude condition is l(t) ≥ L.

5. The tower crane slewing and travel safety linkage control system according to claim 4, characterized in that: The specific process of generating a multi-level execution trigger signal according to the dangerous prediction time T includes: The double-track logic linkage judgment module pre-stores preset multi-level critical time thresholds T1, T2, T3, and T1 > T2 > T3 > 0; When the dangerous prediction time T satisfies: T2 < T ≤ T1, a first-level warning signal is generated; When the danger prediction time T satisfies: T3 < T ≤ T2, a secondary speed limit signal is generated; When the danger prediction time T satisfies: 0 < T ≤ T3, a tertiary pre-braking signal is generated.

6. The tower crane slewing and travel safety linkage control system according to claim 5, characterized in that: The specific operation process of the core control module includes: When a safety braking signal is received, a braking instruction is triggered to lock the forward (towards the direction of increasing amplitude) driving circuit of the trolley, and only allows the trolley to run backward (towards the direction of decreasing amplitude). The braking is automatically released after exiting the danger area; When a primary warning signal is received, a warning prompt instruction is triggered to display warning information through the human-machine interaction unit and / or trigger a prompt audible and visual alarm; When a secondary speed limit signal is received, a speed limit instruction is triggered to control the driving device of the hook trolley to send a speed limit instruction to limit the maximum allowable speed to a preset value; When a tertiary pre-braking signal is received, a pre-braking instruction is triggered to control the driving device of the hook trolley to send a deceleration ramp instruction, so that the hook trolley smoothly decelerates at a preset deceleration.

7. A method for safety linkage control of tower crane slewing and travel, employing a tower crane slewing and travel safety linkage control system as described in any one of claims 1-6, characterized in that, It includes the following steps: S1. Real-time acquisition of tower crane data: Real-time acquisition of the current position data and current speed data of the tower crane. The current position data includes the slewing angle value α and the trolley amplitude value l. The current speed data includes the slewing angular velocity ω and the trolley linear velocity v; S2. Prospective prediction of the tower crane motion state: Based on the current position data and current speed data, predict the future motion trajectory of the hook; S3. Dual-rail linkage judgment: S31. Based on the current position data, determine whether the current hook position point simultaneously satisfies the preset dangerous angle condition and dangerous amplitude condition. When satisfied, generate a safety braking signal; S32. Based on the future motion trajectory, judge whether there is a hook position point that simultaneously satisfies the preset dangerous angle condition and dangerous amplitude condition within a preset future time period. When satisfied, obtain the position point that satisfies the preset dangerous angle condition and dangerous amplitude condition; S33. Determine the danger prediction time based on the time corresponding to the position point, and generate multi-level intervention signals according to the danger prediction time; S4. Control execution: Respond to the safety braking signal and multi-level intervention signals, trigger the operation instructions corresponding to the signals, and perform safety operations based on the operation instructions.

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