Whole-domain hoisting early-warning control method, device and equipment for crane and medium

Abstract

The invention relates to the field of crane control, in particular to a global hoisting early warning control method, device and equipment of a crane and a medium. The rated hoisting capacity of each rotation position of the crane is obtained, the hoisting capacity of different positions can be accurately mastered, and compared with unified rated hoisting capacity design, the performance of each position can be fully utilized, and the hoisting performance utilization rate of the whole crane is improved. Secondly, the current lifting load parameters are obtained, the unbalance early-warning rotation area is determined in combination with the rated lifting weight, and the dangerous area can be recognized in advance. And then, when the crane moves to the area, rotation safety limitation is carried out, so that a dangerous state can be avoided. And finally, the hoisting capacity of each position and the early warning limitation are accurately mastered, so that the crane can work in a more compact space, and the situation that the crane blindly enters a dangerous area and needs to be adjusted in a larger space is avoided, so that the operation requirements of part of harsh and narrow spaces are met, and the problems of the existing scheme are solved.

Description

A method, device, equipment and medium for full-range load warning control of a crane Technical Field

[0001] This invention relates to the field of crane control, specifically to a method, device, equipment, and medium for full-range load warning control of a crane. Background Technology

[0002] With the rapid advancement of urbanization and infrastructure projects, wheeled cranes, due to their flexibility and mobility, are widely used in various scenarios such as building construction and equipment installation. However, in specific operating environments such as the renovation of old urban residential areas and construction in narrow alleyways, limited space becomes a prominent issue, preventing crane outriggers from being fully extended as required by regulations. According to traditional crane operating standards, operating conditions cannot be met when the outriggers are not fully extended, thus limiting the application of cranes in confined spaces. To address this pain point, crane manufacturers have developed a semi-extended outrigger configuration (i.e., all outriggers are extended to a uniform 50% length), enabling cranes to operate in some confined spaces and alleviating the operational difficulties caused by space constraints to some extent.

[0003] However, existing designs for semi-extended outriggers and similar working conditions still have significant limitations: On the one hand, these working conditions require all outriggers to maintain a consistent extension length. In some scenarios with more stringent space constraints, even in semi-extended mode, the outriggers may still struggle to extend properly, making safe lifting operations impossible. On the other hand, in semi-extended outrigger mode, the crane only provides a single lifting capacity performance table during its 360° rotation, and the rated lifting capacity is based on the minimum safe value across the entire rotation angle, failing to differentiate the lifting capacity according to the actual stability performance at different rotation angles. Especially when the outrigger extension lengths are inconsistent, existing solutions typically use the stability performance corresponding to the shortest outrigger as a benchmark to determine the rated lifting capacity, further reducing the utilization rate of the overall lifting performance and resulting in the crane's operational potential within the safety boundaries not being fully realized. Summary of the Invention

[0004] In view of this, embodiments of the present invention provide a method, device, equipment and medium for full-range lifting load early warning control of a crane, in order to solve the problems that the existing outrigger extension and adaptation schemes cannot meet the operational requirements of some harsh and narrow spaces, and the overall lifting performance utilization rate is low due to the adoption of a unified rated lifting load design.

[0005] In a first aspect, embodiments of the present invention provide a method for full-range lifting load early warning control of a crane. The method includes: obtaining the rated lifting weight corresponding to each position of the crane during rotation; obtaining the current lifting load parameters of the crane, and using the lifting load parameters and the rated lifting weight to determine the imbalance warning rotation area of ​​the crane within the full-range rotation area; if the direction of movement of the crane points to the imbalance warning rotation area, then the crane is subject to rotation safety restrictions.

[0006] Furthermore, obtaining the rated lifting weight corresponding to each position of the crane during rotation includes: based on the structural attitude parameters of each component of the crane; and using the structural attitude parameters to calculate the rated lifting weight corresponding to each position of the crane during rotation.

[0007] Furthermore, determining the imbalance warning slewing zone of the crane within the entire slewing area using the lifting load parameters and the rated lifting weight includes: obtaining the actual lifting weight and amplitude data corresponding to each position from the lifting load parameters; comparing the actual lifting weight with the rated lifting weight at each position within the entire slewing area to obtain the load safety factor at each position; calculating the actual lifting torque of the crane at each position using the amplitude data; and selecting the imbalance warning slewing zone within the entire slewing area based on the load safety factor and the actual lifting torque at each position.

[0008] Furthermore, the step of filtering out the imbalance warning turning area within the entire turning range based on the load safety factor and actual lifting torque at each location includes: obtaining the lower limit of the load safety factor and the range of lifting torque at each location; comparing the load safety factor at each location with the corresponding lower limit of the load safety factor, and comparing the actual lifting torque at each location with the corresponding range of lifting torque; and identifying any location where the load safety factor is less than the corresponding lower limit or the actual lifting torque does not fall within the corresponding allowable range as the imbalance warning turning area within the entire turning range.

[0009] Furthermore, the method of limiting the slewing safety of the crane includes: detecting the distance between the crane at its current position and the imbalance warning slewing area; determining the deceleration gradient of the crane based on the distance; controlling the crane to decelerate to the boundary of the imbalance warning slewing area based on the deceleration gradient, and stopping at the boundary of the imbalance warning slewing area.

[0010] Furthermore, the method also includes: analyzing the handle movements of the operator inside the crane before the crane stops at the boundary of the imbalance warning slewing zone; predicting the operator's work requirements based on the handle movements; and outputting adjustment suggestions corresponding to the work requirements after the crane stops at the boundary of the imbalance warning slewing zone.

[0011] Furthermore, after imposing slewing safety restrictions on the crane, the method further includes: monitoring environmental changes in the environment where the crane is located; using the environmental changes to correct the lower limit of the load safety factor and the lifting torque range, and redetermining the imbalance warning slewing area.

[0012] Secondly, embodiments of the present invention provide a full-range lifting load early warning control device for a crane. The device includes: a first acquisition module, used to acquire the rated lifting weight corresponding to each position of the crane during rotation; a second acquisition module, used to acquire the current lifting load parameters of the crane, and use the lifting load parameters and the rated lifting weight to determine the imbalance early warning rotation area of ​​the crane within the full-range rotation area; and a control module, used to impose rotation safety restrictions on the crane if the crane's direction of movement points to the imbalance early warning rotation area.

[0013] Thirdly, embodiments of the present invention provide a computer device, including: a memory and a processor, the memory and the processor being communicatively connected to each other, the memory storing computer instructions, and the processor executing the computer instructions to perform the method described in the first aspect or any corresponding embodiment thereof.

[0014] Fourthly, embodiments of the present invention provide a computer-readable storage medium storing computer instructions that cause a computer to perform the method described in the first aspect or any of its corresponding embodiments.

[0015] This invention obtains the rated lifting capacity at each position of the crane's slewing, enabling precise control of the lifting capacity at different locations. Compared to a standardized rated lifting capacity design, this allows for full utilization of the performance at each position, improving the overall lifting capacity utilization rate of the crane. Secondly, by acquiring the current lifting load parameters and combining them with the rated lifting capacity, an imbalance warning slewing zone can be determined, allowing for early identification of dangerous areas. Then, when the crane moves towards this zone, a slewing safety restriction is applied, preventing entry into a dangerous state. Finally, precise control of the lifting capacity at each position and early warning restrictions allow the crane to operate in more compact spaces, avoiding the need for larger adjustments due to blindly entering dangerous areas. This meets the requirements for operating in some demanding and confined spaces, solving the problems of existing solutions. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 is a flowchart illustrating a crane's full-area lifting load early warning control method according to some embodiments of the present invention; Figure 2 is a schematic diagram illustrating the calculation of the rated lifting weight according to some embodiments of the present invention; Figure 3 is a schematic diagram illustrating the slewing safety limitation of a crane according to some embodiments of the present invention; Figure 4 is a structural block diagram of a crane's full-area lifting load early warning control device according to an embodiment of the present invention; Figure 5 is a hardware structure schematic diagram of a computer device according to an embodiment of the present invention. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] According to embodiments of the present invention, a method, apparatus, device, and medium for full-range load warning control of a crane are provided. It should be noted that the steps shown in the flowcharts in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowcharts, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0020] This embodiment provides a method for full-range lifting load early warning control of a crane. Figure 1 is a flowchart of a method for full-range lifting load early warning control of a crane according to an embodiment of the present invention. As shown in Figure 1, the process includes the following steps: Step S101, obtain the rated lifting load corresponding to each position of the crane during the rotation process.

[0021] In this embodiment of the application, the rated lifting weight corresponding to each position of the crane during the rotation process is obtained, including the following steps A1-A2: Step A1, based on the structural attitude parameters of each component of the crane.

[0022] Specifically, the crane's built-in sensor system (such as weight sensors, angle sensors, and displacement sensors) and parameter preset module are used to acquire multi-dimensional core data: First, basic parameters of each component, including the weight of key components such as the boom, slewing platform, chassis, and counterweight, and their respective center of gravity coordinates (establishing a coordinate system with the crane's slewing center as the origin to accurately locate the three-dimensional spatial position of each center of gravity); second, operating posture parameters, covering the current actual length of the boom (including the extension length of the main boom and auxiliary boom), the boom elevation angle (the angle with the horizontal direction), and the actual extension length of each outrigger (collecting the extension amount of each outrigger separately, supporting asymmetrical extension scenarios); third, slewing-related parameters, including the crane's current slewing angle, and the preset slewing angle sampling interval (e.g., one sampling point every 1°, acquiring a total of 360 slewing position data) to cover the 360° full-domain calculation requirements. All collected parameters must be synchronously transmitted to the control unit. After data verification (removing outliers and supplementing missing data), a standardized set of structural posture parameters is formed to ensure the accuracy of subsequent calculations.

[0023] Step A2: Calculate the rated lifting weight of the crane at each position during the rotation process using structural attitude parameters.

[0024] Specifically, firstly, based on the weight of each component, the coordinates of the center of gravity, and the current slewing angle, the stabilizing moment of the entire machine at that slewing position is calculated (i.e., the sum of the moments generated by the gravity of each component on the slewing center to prevent the crane from overturning, with a focus on the boundary of the stable area formed by the outrigger support points); secondly, combining parameters such as the boom length and elevation angle, the formula for calculating the overturning moment generated by the load weight on the slewing center is derived; finally, based on the safety criterion of "stabilizing moment ≥ overturning moment × safety factor," the maximum allowable load weight at that slewing position is deduced, i.e., the rated lifting weight at that position. For each sampling position of the 360° slewing (e.g., the position corresponding to each 1°), the above moment balance calculation process is repeated, ultimately forming a rated lifting weight dataset covering the entire slewing area, achieving differentiated matching of lifting capacity under different slewing angles.

[0025] As an example, as shown in Figure 2, taking the operation of a wheeled crane as an example, the structural and attitude parameters are first collected, including: boom length of 18m, boom angle (elevation angle) of 30°, outriggers with asymmetrical extension (left front outrigger extends 1.2m, right front outrigger extends 0.8m, rear outrigger extends 1.0m), and current slewing angle of 45°. Simultaneously, parameters of each component are retrieved (boom weight 8t, center of gravity distance from slewing center 3m; chassis weight 20t, center of gravity distance from slewing center 0.5m; counterweight 15t, center of gravity distance from slewing center 2m). These parameters are input into the mechanical balance and stability calculation module. Through the principle of torque balance, the rated lifting weight corresponding to the 45° slewing position is calculated to be 5t. Then, the rated lifting weight for other slewing angles within 360° is calculated (e.g., rated lifting weight of 6t at 90° position, 4.5t at 180° position). Finally, a set of rated lifting weights covering the 360° slewing area is output, clarifying the safe lifting capacity at different positions.

[0026] Step S102: Obtain the current lifting load parameters of the crane, and use the lifting load parameters and rated lifting weight to determine the imbalance warning slewing area of ​​the crane in the full slewing area.

[0027] In this embodiment of the application, the imbalance warning slewing area of ​​the crane in the full slewing area is determined by using the lifting load parameters and the rated lifting weight, including the following steps B1-B4: Step B1, obtain the actual lifting weight and amplitude data corresponding to each position from the lifting load parameters.

[0028] Specifically, the actual lifting weight (including the total weight of the load and lifting gear) is collected in real time during operation using equipment such as the crane's force limiter and weight sensors, ensuring data real-time performance and accuracy. Simultaneously, amplitude data corresponding to each slewing position is collected based on amplitude sensors. Amplitude data represents the horizontal distance from the crane's slewing center to the load's center of gravity. This data needs to be combined with the current slewing angle, boom length, and elevation angle, and geometric calculations are used to correct the original sensor data, eliminating deviations caused by installation errors. For each preset sampling position in the 360° slewing (e.g., one point per 1°), the actual lifting weight and the corrected amplitude data are synchronously linked, forming a one-to-one correspondence dataset of "slewing position - actual lifting weight - amplitude," ensuring that subsequent analysis covers the entire slewing range without data omission.

[0029] Step B2: For each position within the full-range slewing area, compare the actual lifting weight at that position with the rated lifting weight to obtain the load safety factor for each position.

[0030] Specifically, the calculated rated lifting weight at each slewing position is retrieved and compared point-by-point with the corresponding actual lifting weight. The load-bearing state at each position is quantified using the formula "load safety factor = actual lifting weight / rated lifting weight." A coefficient less than 1 indicates the current load is within a safe range; equal to 1 indicates it is close to the safety threshold; and greater than 1 indicates it exceeds the rated load capacity. By calculating the load safety factor at each position, this approach replaces the conservative design of the existing scheme that uses the minimum rated lifting weight as a benchmark, accurately reflecting the actual safety margin at different slewing angles and providing a quantitative basis for subsequent risk area screening.

[0031] Step B3: Calculate the actual lifting torque of the crane at each position using the amplitude data.

[0032] Specifically, the lifting moment, a key stability parameter for crane slewing operations, is calculated using the formula: "Actual lifting moment = Actual lifted weight × Amplitude". For each position within the entire slewing range, the corresponding actual lifted weight and corrected amplitude data are substituted to perform point-by-point moment calculations. During the calculation, the crane's slewing center is used as the moment equilibrium point, and the influence of the boom elevation angle on the amplitude is considered (by correcting the horizontal projection distance of the amplitude using trigonometric functions) to ensure the accuracy of the moment calculation. This ultimately establishes the correspondence between each slewing position and the actual lifting moment, providing mechanical support for subsequent risk assessment based on the allowable stability range.

[0033] Step B4: Based on the load safety factor and actual lifting torque at each location, select the imbalance warning slewing area within the entire slewing area.

[0034] Specifically, based on the load safety factor and actual lifting moment at each location, imbalance warning slewing zones within the entire slewing area are selected, including: obtaining the lower limit of the load safety factor and the lifting moment range at each location; comparing the load safety factor at each location with the corresponding lower limit of the load safety factor, and comparing the actual lifting moment at each location with the corresponding lifting moment range; and identifying locations where either the load safety factor is less than the corresponding lower limit or the actual lifting moment does not fall within the corresponding allowable range as imbalance warning slewing zones within the entire slewing area.

[0035] Specifically, firstly, based on the crane's structural design parameters (such as outrigger support span, chassis weight, and material strength limit), operational safety standards, and equipment factory calibration data, a lower limit for the load safety factor (used to quantify the safety threshold for load bearing) and an allowable range for stable lifting torque (including upper and lower limits, defining the torque range to prevent overturning) are preset for each position within the full-range slewing area. Then, for each sampling position in the 360° slewing, a dual-indicator comparison is performed: on the one hand, the calculated load safety factor for that position is compared numerically with the preset lower limit to determine if it is below the safety threshold; on the other hand, the calculated actual lifting torque is checked against the preset allowable range to determine if it exceeds the upper and lower limits. Finally, the comparison results for all positions are filtered, and positions that meet either the condition of "load safety factor less than the corresponding lower limit" or "actual lifting torque not falling within the corresponding allowable range" are integrated to form a continuous or discrete set of regions. This set is the imbalance warning slewing area within the full-range slewing area.

[0036] As an example, the 360° rotation area of ​​the crane is divided into 360 sampling points in 1° increments. The lower limit of the load safety factor for each location is preset to be 0.9, and the allowable range of lifting torque stability is 80kN. m~150kN m. For a position with a rotation angle of 20°, the calculated load safety factor is 0.85 (less than the lower limit of 0.9), and the actual lifting moment is 140kN. m (falling within the allowable range), because it meets the condition of "load safety factor less than the corresponding lower limit", this position is included in the imbalance warning rotation zone; for the position with a rotation angle of 120°, its load safety factor is 0.95 (greater than the lower limit of 0.9), and the actual lifting moment is 160kN. m (exceeding the upper limit of the allowable range), this position is also included because it meets the condition that "the actual lifting moment does not fall within the corresponding allowable range"; for the position with a slewing angle of 250°, the load safety factor is 0.92 and the actual lifting moment is 130kN. All locations with a value of m meet the safety requirements and are therefore not included in the warning area. Ultimately, all locations that meet any of the above conditions (such as 20°, 120°, 121°, etc.) are integrated to form the imbalance warning rotation area.

[0037] Step S103: If the crane's movement direction points towards the imbalance warning slewing area, then the crane's slewing safety restriction is applied.

[0038] In this embodiment of the application, the slewing safety limitation of the crane includes: detecting the distance between the crane at its current position and the imbalance warning slewing area; determining the deceleration gradient of the crane based on the distance; controlling the crane to decelerate to the boundary of the imbalance warning slewing area based on the deceleration gradient, and stopping at the boundary of the imbalance warning slewing area.

[0039] In practice, the current real-time slewing angle (e.g., θ0) is first obtained using the crane's slewing angle sensor, and the angle range of the pre-determined imbalance warning slewing zone (e.g., θ1~θ2, including continuous or discrete angle segments) is retrieved. Using the slewing center as a reference, the angular distance is converted into a calculable physical distance or angle difference—if the current angle θ0 is to the left of the warning zone (θ0<θ1), the distance is θ1-θ0; if it is to the right (θ0>θ2), the distance is θ0-θ2; if the current position has partially entered the warning zone, the distance is 0. During the calculation, the difference between the current angle and the boundary of the warning zone needs to be updated in real time to eliminate interference from slewing mechanism clearance, sensor errors, etc. Data accuracy is optimized by averaging multiple samples to ensure that the distance detection result accurately reflects the actual relative positional relationship between the two.

[0040] The system pre-determines the mapping relationship between multiple distance thresholds and corresponding deceleration forces (e.g., when the distance is ≥10°, the deceleration gradient is 0, maintaining normal speed; when the distance is 5°≤distance<10°, the deceleration gradient is 30%, reducing the slewing speed by 30%; when the distance is <5°, the deceleration gradient is 70%, significantly reducing the speed). The deceleration gradient needs to be calibrated in conjunction with parameters such as the power performance of the crane's slewing mechanism and the inertia of the load. When the detected distance falls within the corresponding threshold range, the system automatically matches the pre-deceleration gradient and adjusts it in real time according to distance changes—if the distance shortens too quickly (e.g., the operator does not decelerate), the deceleration gradient is dynamically increased; if the distance remains unchanged or increases (e.g., the operator actively moves away from the warning area), the deceleration gradient is reduced or canceled, ensuring that the deceleration process is both efficient and avoids excessive braking that affects operational efficiency.

[0041] The determined deceleration gradient is converted into a drive signal for the slewing mechanism (e.g., adjusting the motor output voltage or controlling the hydraulic valve opening), driving the slewing mechanism to gradually reduce its speed according to the preset gradient. Simultaneously, the crane's slewing angle is monitored in real time, comparing the current position with the boundary angle (θ1 or θ2) of the imbalance warning slewing zone. When the current angle is detected to be close to the boundary (e.g., difference ≤ 0.5°), the deceleration gradient is further increased to 100% to achieve smooth deceleration. When the current angle reaches the boundary angle, a stop command is immediately triggered, cutting off the drive power of the slewing mechanism and simultaneously activating the mechanical locking device (e.g., electromagnetic brake) to prevent the crane from crossing the boundary due to inertia. Throughout the process, position and speed signals are continuously fed back, forming a closed-loop control system to ensure precise and reliable deceleration and stopping actions, balancing operational safety and equipment stability.

[0042] As an example, as shown in Figure 3, taking a wheeled crane operating in a narrow space as an example, suppose it is currently at a certain position in the counterclockwise rotation direction. The system has already calculated and determined the clockwise rotation boundary (i.e., the boundary of the imbalance warning rotation area). At this time, the actual lifting weight of the crane is 4t, the amplitude data is 8m, and combined with the rated lifting weight of 5t at the corresponding rotation position, the load safety factor is calculated to be 0.8 (less than the preset lower limit of 0.9), and the actual lifting moment is 32kN. m (exceeding the upper limit of the allowable range of this location by 30kN) The corresponding area in the clockwise direction (m) has been marked as the imbalance warning slewing zone. When the crane moves clockwise, the system detects that the current position is 3° away from the clockwise slewing boundary. Then, according to the preset strategy, it determines the deceleration gradient to 70%, controls the crane to gradually decelerate, and finally stops smoothly at the clockwise slewing boundary, avoiding entering the imbalance warning zone.

[0043] In this embodiment of the application, the method further includes: analyzing the handle movements of the operator inside the crane before the crane stops at the boundary of the imbalance warning slewing zone; predicting the operator's work requirements based on the handle movements; and outputting adjustment suggestions corresponding to the work requirements after the crane stops at the boundary of the imbalance warning slewing zone.

[0044] Specifically, using the displacement and pressure sensors built into the crane's operating handle, the system collects real-time data on the handle's movement parameters, including the direction of push (consistent with the crane's rotation direction), the magnitude of the push (percentage of travel), duration, rate of motion (displacement change per unit time), and whether reciprocating motion is present. The control unit analyzes the collected parameters in real time: if the handle is continuously pushed towards the imbalance warning area with a stable magnitude, it indicates the operator may need to complete lifting operations in that area; if the magnitude of the push is small and frequent adjustments are made, it may be a trial operation or a search for a safe operating angle; if the handle is quickly pushed and immediately returned to its original position, it may be a misoperation. Simultaneously, by considering the crane's current operating scenario (such as the position of the load and the distribution of surrounding obstacles), invalid operation signals (such as slight handle vibrations) are filtered out to ensure that the analysis of the operator's handle movements accurately reflects their true operational trend.

[0045] Establish a mapping model between handle motion characteristics and operational requirements: When the handle is continuously pushed towards the warning area, reaching a preset threshold (e.g., 70% of full stroke) and lasting for more than a set value (e.g., 2 seconds), combined with the target object's position coordinates (if the system is connected), it is predicted that the operator needs to transfer the object to a designated location within the warning area. If the handle push is small, involves numerous reciprocating adjustments, and the object is not currently positioned, it is predicted that the operator needs to find a suitable safe slewing angle to complete the operation. If the handle is quickly pushed and immediately returns to its original position without any accompanying operations (e.g., luffing or hoisting), it is predicted to be a misoperation, and the operational requirement is to avoid the danger zone. During the prediction process, the crane's current rated lifting capacity and the range of the imbalance warning area are simultaneously correlated to ensure that the predicted operational requirements match the equipment's safety status and avoid misjudgments of requirements that deviate from actual safety boundaries.

[0046] If the system anticipates needing to operate within the warning area, it outputs "It is recommended to reduce the actual lifting weight to below m tons (current safety threshold), or adjust the outrigger extension length (e.g., extend the right outrigger by n meters). The system will recalculate the safety boundary, allowing the operator to turn back to the target area." If the system anticipates needing to find a safe angle, it outputs "It is recommended to turn to the left by w° (safe area direction). At this angle, the rated lifting weight meets the current load requirements and the operation can be completed normally." If the system anticipates an operational error, it outputs "An imbalance warning has been triggered. There is a risk of overturning in the current direction. It is recommended to turn back to the safe area in the opposite direction." Adjustment suggestions are displayed visually on the cab screen, accompanied by voice announcements (e.g., "Please reduce the lifting weight and try again"), ensuring the operator quickly obtains key information. The suggestions must clearly state the operating steps, adjustment parameters, and expected effects, avoiding vague descriptions. A manual adjustment interface is also provided, allowing the operator to flexibly optimize based on the actual site conditions.

[0047] In this embodiment of the application, after limiting the slewing safety of the crane, the method further includes: monitoring the environmental changes of the environment in which the crane is located; using the environmental changes to correct the lower limit of the load safety factor and the range of lifting torque, and redetermining the imbalance warning slewing area.

[0048] By installing environmental sensors at key locations such as the crane body and boom, multi-dimensional environmental data is continuously collected: wind speed sensors monitor real-time wind speed and direction in the work area (with a focus on instantaneous gust intensity to prevent strong winds from causing load swaying and overall machine imbalance); tilt sensors detect changes in ground slope (slope shifts caused by ground subsidence, work site modifications, etc., can affect the stability of outrigger support); temperature sensors collect ambient temperature (extreme temperatures may affect material mechanical properties and hydraulic system efficiency); in some scenarios, humidity sensors and visibility sensors can be added (for outdoor operations in complex weather). Sensor data is transmitted to the control unit at a preset frequency (e.g., 5 times per second). After data filtering and outlier removal (e.g., instantaneous false alarms from wind speed sensors), a standardized environmental change dataset is formed, providing real-time feedback on the dynamic fluctuations of environmental parameters.

[0049] The established environmental parameters and safety threshold correction model are obtained as follows: When the wind speed exceeds the preset safety value (e.g., level 6 wind, wind speed 10.8 m / s), the lower limit of the load safety factor is linearly reduced according to the wind speed level (e.g., the lower limit is reduced by 0.1 for each level increase in wind), and the allowable range of lifting torque is reduced (e.g., reduced by 10%-15%) to avoid the increased inertia of the suspended object caused by strong winds, which could lead to overturning; when the ground slope exceeds 3°, the lifting torque range is adjusted according to the slope direction (e.g., the upper limit is further reduced in the downhill direction), and the lower limit of the load safety factor is appropriately reduced to compensate for the uneven force on the outrigger support; when the ambient temperature exceeds the equipment's operating temperature range (e.g., below -10℃ or above 40℃), the lower limit of the load safety factor is reduced by 5%-10% to adapt to changes in material strength and hydraulic system performance. Based on the revised lower limit of the load safety factor and the lifting torque range, the filtering logic of step B4 is resubmitted to perform a second verification of the load safety factor and actual lifting torque at each position within the 360° rotation area. Positions in the original warning area that have become safe due to environmental improvement are removed, and risk positions caused by environmental deterioration are added, ultimately forming the updated imbalance warning rotation area.

[0050] This embodiment also provides a crane's full-range load warning control device, which is used to implement the above embodiments and preferred embodiments; details already described will not be repeated. As used below, the term "module" can refer to a combination of software and / or hardware that implements a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0051] This embodiment provides a full-range lifting load early warning control device for a crane, as shown in Figure 4, including: a first acquisition module 401, used to acquire the rated lifting weight corresponding to each position of the crane during the rotation process; a second acquisition module 402, used to acquire the current lifting load parameters of the crane, and use the lifting load parameters and the rated lifting weight to determine the imbalance warning rotation area of ​​the crane in the full-range rotation area; and a control module 403, used to impose rotation safety restrictions on the crane if the crane's movement direction points to the imbalance warning rotation area.

[0052] In this embodiment of the application, the first acquisition module 401 is used to calculate the rated lifting weight of the crane at each position during the rotation process based on the structural attitude parameters of each component of the crane.

[0053] In this embodiment of the application, the second acquisition module 402 is used to acquire the actual lifting weight and amplitude data corresponding to each position from the lifting load parameters; for each position in the full-range slewing area, the actual lifting weight of that position is compared with the rated lifting weight to obtain the load safety factor of each position; the actual lifting torque of the crane at each position is calculated using the amplitude data; and the imbalance warning slewing area in the full-range slewing area is screened out based on the load safety factor and the actual lifting torque of each position.

[0054] In this embodiment of the application, the second acquisition module 402 is used to acquire the lower limit of the load safety factor and the lifting moment range of each position; compare the load safety factor of each position with the corresponding lower limit of the load safety factor, and compare the actual lifting moment of each position with the corresponding lifting moment range; and take any position where the load safety factor is less than the corresponding lower limit or the actual lifting moment does not fall into the corresponding allowable range as the imbalance warning turning area within the whole domain turning area.

[0055] In this embodiment, the control module 403 is used to detect the distance between the crane at its current position and the imbalance warning slewing area; determine the deceleration gradient of the crane based on the distance; control the crane to decelerate to the boundary of the imbalance warning slewing area based on the deceleration gradient, and stop at the boundary of the imbalance warning slewing area.

[0056] In this embodiment of the application, the device further includes: a prompting module, used to analyze the handle movements of the operator inside the crane before the crane stops at the boundary of the imbalance warning slewing zone; predict the operator's work requirements based on the handle movements; and output adjustment suggestions corresponding to the work requirements after the crane stops at the boundary of the imbalance warning slewing zone.

[0057] In this embodiment of the application, the device further includes: a monitoring module, used to monitor environmental changes in the environment where the crane is located; to use the environmental changes to correct the lower limit of the load safety factor and the lifting torque range, and to redetermine the imbalance warning slewing area.

[0058] Please refer to Figure 5, which is a schematic diagram of a computer device according to an optional embodiment of the present invention. As shown in Figure 5, the computer device includes one or more processors 10, a memory 20, and interfaces for connecting the various components, including high-speed interfaces and low-speed interfaces. Each component communicates with each other using different buses and can be installed on a common motherboard or otherwise as needed. The processor can process instructions executed within the computer device, including instructions stored in or on memory to display graphical information of a GUI on an external input / output device (such as a display device coupled to the interface). In some optional embodiments, multiple processors and / or multiple buses can be used with multiple memories and multiple memory modules, if desired. Similarly, multiple computer devices can be connected, each providing some of the necessary operations (e.g., as a server array, a group of blade servers, or a multiprocessor system).

[0059] Processor 10 may be a central processing unit, a network processor, or a combination thereof. Processor 10 may further include a hardware chip. The hardware chip may be an application-specific integrated circuit (ASIC), a programmable logic device (PLD), or a combination thereof. The programmable logic device may be a complex programmable logic device (CAMP), a field-programmable gate array (FPGA), a general-purpose array logic (GPA), or any combination thereof.

[0060] The memory 20 stores instructions executable by at least one processor 10 to cause the at least one processor 10 to perform the method shown in the above embodiments.

[0061] The memory 20 may include a program storage area and a data storage area. The program storage area may store the operating system and applications required for at least one function; the data storage area may store data created based on the use of the computer device as shown by a landing page for an app. Furthermore, the memory 20 may include high-speed random access memory and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some alternative embodiments, the memory 20 may optionally include memory remotely located relative to the processor 10, which can be connected to the computer device via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0062] The memory 20 may include volatile memory, such as random access memory; the memory may also include non-volatile memory, such as flash memory, hard disk or solid-state drive; the memory 20 may also include a combination of the above types of memory.

[0063] The computer device also includes a communication interface 30 for communicating with other devices or communication networks.

[0064] This invention also provides a computer-readable storage medium. The methods described above according to embodiments of the invention can be implemented in hardware or firmware, or implemented as computer code that can be recorded on a storage medium, or implemented as computer code downloaded via a network and originally stored on a remote storage medium or a non-transitory machine-readable storage medium and then stored on a local storage medium. Thus, the methods described herein can be processed by software stored on a storage medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware. The storage medium can be a magnetic disk, optical disk, read-only memory, random access memory, flash memory, hard disk, or solid-state drive, etc.; further, the storage medium can also include combinations of the above types of memory. It is understood that computers, processors, microprocessor controllers, or programmable hardware include storage components capable of storing or receiving software or computer code, which, when accessed and executed by the computer, processor, or hardware, implements the methods shown in the above embodiments.

[0065] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for full-range load warning control of a crane, characterized in that, The method includes: obtaining the rated lifting weight corresponding to each position of the crane during the slewing process; obtaining the current lifting load parameters of the crane, and using the lifting load parameters and the rated lifting weight to determine the imbalance warning slewing area of ​​the crane in the entire slewing area; if the direction of movement of the crane points to the imbalance warning slewing area, then the crane is subject to slewing safety restrictions.

2. The method according to claim 1, characterized in that, The process of obtaining the rated lifting weight of the crane at each position during rotation includes: based on the structural attitude parameters of each component of the crane; and using the structural attitude parameters to calculate the rated lifting weight of the crane at each position during rotation.

3. The method according to claim 1, characterized in that, The step of determining the imbalance warning slewing zone of the crane within the full slewing area using the lifting load parameters and the rated lifting weight includes: obtaining the actual lifting weight and amplitude data corresponding to each position from the lifting load parameters; comparing the actual lifting weight with the rated lifting weight at each position within the full slewing area to obtain the load safety factor at each position; calculating the actual lifting torque of the crane at each position using the amplitude data; and selecting the imbalance warning slewing zone within the full slewing area based on the load safety factor and the actual lifting torque at each position.

4. The method according to claim 3, characterized in that, The process of selecting imbalance warning slewing zones within the entire slewing area based on the load safety factor and actual lifting torque at each location includes: obtaining the lower limit of the load safety factor and the lifting torque range at each location; comparing the load safety factor at each location with the corresponding lower limit of the load safety factor, and comparing the actual lifting torque at each location with the corresponding lifting torque range; and identifying locations where either the load safety factor is less than the corresponding lower limit or the actual lifting torque does not fall within the corresponding allowable range as imbalance warning slewing zones within the entire slewing area.

5. The method according to claim 1, characterized in that, The method of limiting the slewing safety of the crane includes: detecting the distance between the crane at its current position and the imbalance warning slewing area; determining the deceleration gradient of the crane based on the distance; controlling the crane to decelerate to the boundary of the imbalance warning slewing area based on the deceleration gradient, and stopping at the boundary of the imbalance warning slewing area.

6. The method according to claim 1, characterized in that, The method further includes: analyzing the handle movements of the operator inside the crane before the crane stops at the boundary of the imbalance warning slewing zone; predicting the operator's work requirements based on the handle movements; and outputting adjustment suggestions corresponding to the work requirements after the crane stops at the boundary of the imbalance warning slewing zone.

7. The method according to claim 1, characterized in that, After imposing slewing safety restrictions on the crane, the method further includes: monitoring environmental changes in the environment where the crane is located; using the environmental changes to correct the lower limit of the load safety factor and the lifting torque range, and redetermining the imbalance warning slewing zone.

8. A crane's full-range load warning control device, characterized in that, The device includes: a first acquisition module for acquiring the rated lifting weight corresponding to each position of the crane during slewing; a second acquisition module for acquiring the current lifting load parameters of the crane and using the lifting load parameters and the rated lifting weight to determine the imbalance warning slewing area of ​​the crane within the entire slewing area; and a control module for imposing slewing safety restrictions on the crane if the crane's direction of movement points to the imbalance warning slewing area.

9. A computer device, characterized in that, include: A memory and a processor, the memory and the processor being communicatively connected to each other, the memory storing computer instructions, the processor executing the computer instructions to perform the method of any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions for causing the computer to perform the method of any one of claims 1 to 7.

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