Same-span crane overhaul safety laser limiting device and using method

Abstract

The invention discloses a same-span crane overhaul safety laser limiting device and a using method, and relates to the technical field of crane overhaul safety protection equipment.The same-span crane overhaul safety laser limiting device comprises a movable base, a laser transmitter, a laser receiver, a controller, a warning indicator and a brake linkage interface; the transmitting end is parallel to a crane running track; the laser receiver is mounted on the movable base; the controller is installed on the movable base, and the signal input end of the controller is electrically connected with the signal output end of the laser receiver. The warning indicator is installed on the movable base, and the control end of the warning indicator is electrically connected with the signal output end of the controller. The input end of the brake linkage interface is electrically connected with the signal output end of the controller, the output end of the brake linkage interface is used for being in signal connection with a brake system of a movable crane in same-span operation, the structure is simple, use is convenient, collision accidents during same-span crane overhaul are effectively prevented, and the overhaul operation safety coefficient and the overall operation efficiency are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of crane maintenance safety protection equipment, and in particular to a laser limit device for crane maintenance safety and its usage method. Background Technology

[0002] In scenarios involving multiple cranes operating across the same span, when one crane is undergoing maintenance and is parked, existing safety measures primarily rely on the traditional "roadblocks (physical protection) + red flags (human protection)" model. However, this model has many significant limitations.

[0003] On the one hand, due to the limitations of the on-site workstation layout, crane operators need to visually judge when to slow down and stop by looking at the red flag. However, when the distance between two workstations is too close, or when the crane is too close to the red flag, blind spots are easily created, preventing the operator from spotting the maintenance area in time. On the other hand, even if the operator spots the red flag, the operator may slow down too late, and the inertia of the crane could cause a collision with the red flag and road barriers, leading to serious safety hazards such as equipment damage or even personal injury. According to statistics, in the first half of 2025 alone, there were as many as three minor collision incidents in this scenario.

[0004] Furthermore, traditional protection methods require manual monitoring of the red flag, and the deployment of equipment before maintenance is time-consuming. Additionally, mobile cranes often need to slow down in advance to anticipate distances, which significantly impacts overall operational efficiency. In conclusion, existing technologies lack a comprehensive safety protection solution for same-span crane maintenance that balances reliability, ease of operation, and operational efficiency. Summary of the Invention

[0005] The purpose of this invention is to provide a laser limiting device and its usage method for the safety of cranes in the same span during maintenance, so as to solve the problems existing in the prior art. It has a simple structure, is easy to use, effectively prevents collision accidents during the maintenance of cranes in the same span, and effectively improves the safety factor and overall work efficiency of maintenance operations.

[0006] To achieve the above objectives, the present invention provides the following solution:

[0007] This invention provides a laser-based safety limit device for crane maintenance across the same span, comprising: a movable base, a laser emitter, a laser receiver, a controller, a warning device, and a braking linkage interface.

[0008] The laser emitter is mounted on the movable base, with its emitting end facing parallel to the crane's running track; the laser receiver is mounted on the movable base, with its receiving end corresponding to the emitting end of the laser emitter; the controller is mounted on the movable base, with its signal input end electrically connected to the signal output end of the laser receiver; the warning device is mounted on the movable base, with its control end electrically connected to the signal output end of the controller; the braking linkage interface has its input end electrically connected to the signal output end of the controller, and its output end is used to connect to the braking system signal of the mobile crane operating in the same span.

[0009] Preferably, the braking linkage interface is a wireless communication module, which is wirelessly connected to the controller of the crane braking system.

[0010] Preferably, the braking linkage interface is a wired communication port, which is used to connect to the hardware interface of the crane braking system.

[0011] Preferably, the alarm is an audible and visual alarm, which includes a buzzer and a red flashing light.

[0012] Preferably, the alarm further includes a voice prompt unit, which is electrically connected to the signal output terminal of the controller.

[0013] Preferably, the controller is a microcontroller, which has a pre-set hierarchical control circuit, and the hierarchical control circuit is electrically connected to the laser receiver, the warning device and the braking linkage interface respectively.

[0014] Preferably, the controller also integrates a Bluetooth communication module, which is used to communicate with external terminal devices.

[0015] Preferably, the laser receiver has a filter at its receiving window.

[0016] Preferably, the bottom of the movable base is equipped with casters, a shock-absorbing spring is provided between the casters and the movable base, and the casters are equipped with a brake locking device.

[0017] The present invention also provides a method for using the same-span crane maintenance safety laser limit device as described in any of the preceding claims, characterized by comprising the following steps:

[0018] Step 1: Move the two laser limit devices for maintenance safety of the same span cranes as described above to the safety boundaries on both sides of the maintenance crane along the running track.

[0019] Step 2: Activate the laser emitter so that its emitting end emits a laser beam along the direction of the crane's running track, and the laser receiver of another crane maintenance safety laser limit device as described above receives the laser beam, forming a laser warning line spanning the maintenance area;

[0020] Step 3: When the mobile crane operating in the same span moves to the point of blocking the laser beam, the laser receiver receives the signal change and transmits it to the controller;

[0021] Step 4: The controller controls the alarm to issue an alert based on the received signal;

[0022] Step 5: The controller sends a control signal to the braking system of the mobile crane through the braking linkage interface, causing the mobile crane to decelerate or stop.

[0023] The present invention achieves the following technical effects compared to the prior art:

[0024] This invention provides a laser-based safety limiting device and its usage method for crane maintenance in the same span. The device uses a laser emitter and receiver to form a laser warning line parallel to the crane's running track. When a mobile crane operating in the same span enters the laser warning line, the laser receiver detects the beam being blocked and immediately sends a signal to the controller. The controller triggers an audible and visual alarm and simultaneously sends a braking command to the mobile crane's braking system via a braking linkage interface, achieving automatic deceleration or emergency braking. This fundamentally eliminates safety hazards such as blind spots and delayed response in traditional human and physical security methods, significantly shortens the device deployment time before maintenance, and allows the mobile crane to safely pass through non-maintenance areas without premature deceleration, significantly improving the safety and efficiency of crane maintenance operations in the same span. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 A schematic diagram of the laser limit device for safe maintenance of cranes in the same span provided by the present invention;

[0027] In the picture: 1. Movable base; 2. Laser emitter; 3. Laser receiver; 4. Controller; 5. Alarm device. Detailed Implementation

[0028] 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. 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.

[0029] The purpose of this invention is to provide a laser limiting device and its usage method for the safety of cranes in the same span during maintenance, so as to solve the problems existing in the prior art. It has a simple structure, is easy to use, effectively prevents collision accidents during the maintenance of cranes in the same span, and effectively improves the safety factor and overall work efficiency of maintenance operations.

[0030] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] Example 1

[0032] This embodiment provides a laser-based safety limit device for crane maintenance in the same span, as shown in Figure 1. It includes: a movable base 1, a laser emitter 2, a laser receiver 3, a controller 4, a warning device 5, and a braking linkage interface. The laser emitter 2 is mounted on the movable base 1, with its emitting end parallel to the crane's running track. The laser receiver 3 is mounted on the movable base 1, with its receiving end corresponding to the emitting end of the laser emitter 2. The controller 4 is mounted on the movable base 1, with its signal input end electrically connected to the signal output end of the laser receiver 3. The warning device 5 is mounted on the movable base 1, with its control end electrically connected to the signal output end of the controller 4. The braking linkage interface has its input end electrically connected to the signal output end of the controller 4, and its output end is used to connect to the braking system signal of the crane operating in the same span. This structural design clearly defines the installation position and connection relationship of each component, making the device an organic whole. The laser emitter 2 emits laser light parallel to the crane's running track, facilitating accurate monitoring of the crane's movement along the track. The laser receiver 3 is configured to effectively receive laser signals, and the controller 4 is responsible for processing the signals and controlling the warning device 5 and the braking linkage interface, thereby realizing the safety monitoring and control of the mobile crane and providing a basic framework for the safety protection of the crane during maintenance.

[0033] In a preferred embodiment, the braking linkage interface is a wireless communication module. The wireless communication module is wirelessly connected to the controller 4 of the crane braking system. Using the wireless communication module as the braking linkage interface makes the connection between the device and the crane braking system more flexible, eliminating the need for complex wiring. This facilitates quick installation and deployment in different working environments, and is especially suitable for scenarios where the crane braking system is located in a dispersed manner or where wired connections are difficult, thus improving the versatility and convenience of the device.

[0034] In a preferred embodiment, the braking linkage interface is a wired communication port. The wired communication port is used to connect to the hardware interface of the crane braking system. As a braking linkage interface, the wired communication port can provide a more stable and reliable communication connection, reduce signal interference and transmission delay, and ensure that the braking signal is accurately and timely transmitted to the crane braking system. It is suitable for critical operation scenarios with extremely high requirements for communication stability and where signal loss or mistransmission is not allowed.

[0035] In a preferred embodiment, the warning device 5 is an audible and visual alarm. The audible and visual alarm is equipped with a buzzer and a red flashing light. The audible and visual alarm emits a loud sound through the buzzer and flashes the red flashing light, which can attract the attention of the crane operator and surrounding personnel at the same time through sight and hearing. It can issue a timely warning when the crane approaches the maintenance area, thereby enhancing the warning effect and effectively avoiding dangerous situations caused by lack of concentration.

[0036] In a preferred embodiment, the warning device 5 further includes a voice prompt unit, which is electrically connected to the signal output terminal of the controller 4. The voice prompt unit further enriches the warning methods. Compared with simple sound and light alarms, voice prompts can convey danger information more clearly and explicitly. Especially in noisy working environments, it can help crane operators understand dangerous situations more accurately and improve the effectiveness and recognizability of warnings.

[0037] In a preferred embodiment, the controller 4 is a microcontroller with a pre-installed hierarchical control circuit. This circuit is electrically connected to the laser receiver 3, the warning device 5, and the braking linkage interface. By using the microcontroller as the controller 4 and incorporating the hierarchical control circuit, the warning device 5 and the braking linkage interface can be controlled hierarchically based on different signal states fed back from the laser receiver 3. For example, different levels of warning and braking measures can be implemented at different distances between the crane and the maintenance area, achieving refined and intelligent safety control and effectively improving the safety and adaptability of the device.

[0038] In a preferred embodiment, the controller 4 also integrates a Bluetooth communication module. The Bluetooth communication module is used to communicate with external terminal devices. The integration of the Bluetooth communication module enables the controller 4 to communicate with external terminal devices (such as mobile phones, tablets, etc.), which facilitates operators to perform parameter settings, status monitoring, and other operations on the device from a certain distance. This improves the ease of operation and flexibility of the device and facilitates remote management and maintenance.

[0039] In a preferred embodiment, the laser receiver 3 is provided with a filter at its receiving window. The filter can effectively filter out stray light in the environment, improve the accuracy of the laser receiver 3 in receiving laser light of a specific wavelength emitted by the laser transmitter 2, enhance the anti-interference capability of the device in complex lighting environments, ensure that the laser receiver 3 can work stably and reliably, and avoid misjudgment caused by ambient light interference.

[0040] In a preferred embodiment, the movable base 1 is equipped with casters at its bottom, and a shock-absorbing spring is provided between the casters and the movable base 1. The casters are equipped with a brake locking device. The casters allow the device to move flexibly in different positions, and the device position can be quickly adjusted according to actual operational needs. The shock-absorbing spring reduces vibrations caused by uneven ground or other factors during movement, protecting internal electronic components and extending the device's service life. The brake locking device secures the device after it reaches the designated position, ensuring stability and preventing displacement during operation, thus guaranteeing the accuracy of safety monitoring.

[0041] Example 2

[0042] This embodiment also provides a method for using the same-span crane maintenance safety laser limit device as described in any of the above embodiments, including the following steps:

[0043] 1. Preliminary preparations

[0044] Device Selection and Inspection: Based on the actual conditions of the work site, such as the characteristics of the crane braking system and the complexity of the working environment, select a suitable laser limit device for crane maintenance in the same span from various braking linkage interface types (wireless communication module or wired communication port) and different warning device configurations (whether it includes a voice prompt unit, etc.). Carefully inspect each component of the selected device to ensure that the movable base 1 is undamaged, the casters and brake locking devices are functioning properly, the shock-absorbing springs are in good elasticity, the laser transmitter 2 and receiver are in good condition, the filter is securely installed, and the electronic components such as the controller 4, warning device 5, and braking linkage interface are fault-free, and the connections between all components are stable.

[0045] Equipment Connection and Debugging: If the braking linkage interface is a wireless communication module, it needs to be paired and parameter-set with the crane braking system controller 4 in advance to ensure the stability and accuracy of wireless communication. If it is a wired communication port, accurately connect it to the hardware interface of the crane braking system and check whether the connection is secure. At the same time, turn on the power of the device and check whether each component is powered on and working normally. For the controller 4 with an integrated Bluetooth communication module, it can be paired and connected to the Bluetooth communication module through an external terminal device (such as a mobile phone or tablet computer) to perform preliminary parameter settings for the device, such as the distance threshold of the graded control circuit and the volume of the alarm 5.

[0046] 2. Arrangement of equipment and setting up of warning lines

[0047] Device Positioning: Move the two selected and inspected laser safety limit devices for the same span cranes to the safety boundaries on both sides of the crane's running track. Determining the safety boundaries requires comprehensive consideration of factors such as the crane's operating speed, braking performance, and the working environment to ensure the mobile crane has sufficient reaction time before entering the hazardous area.

[0048] Start-up and Calibration: Start laser transmitter 2 so that its emitting end emits a laser beam along the direction of the crane's running track. Adjust the position and angle of the device so that the laser receiver 3 of the other device can accurately receive the laser beam, forming a laser warning line spanning the maintenance area. During the adjustment process, the parallelism and alignment accuracy of the laser beam can be ensured by observing the signal indicator lights of the laser receiver 3 or by using professional laser calibration equipment, thus guaranteeing the reliability of the laser warning line.

[0049] 3. Monitoring and Response During Operations

[0050] Real-time monitoring: During the operation of the crane in the same span, the laser emitter 2 continuously emits a laser beam, and the laser receiver 3 monitors in real time whether the laser beam is blocked. Once the crane operating in the same span moves to the point of blocking the laser beam, the laser receiver 3 receives a change in signal and quickly transmits the signal to the controller 4.

[0051] Warning and Braking Control: Upon receiving a signal, controller 4 controls the warning device 5 to issue a corresponding warning according to the preset hierarchical control circuit logic. If the warning device 5 includes a voice prompt unit, it will clearly convey danger information, such as "Entering a maintenance area ahead, please slow down," etc. Simultaneously, controller 4 sends a control signal to the braking system of the mobile crane via the braking linkage interface. Based on the distance between the crane and the maintenance area and the preset hierarchical control strategy, it controls the mobile crane to decelerate or stop. For example, when the crane is far from the maintenance area, a deceleration signal is sent, causing the crane to decelerate at a certain acceleration; when the crane is close to the maintenance area and has not decelerated in time, a stop signal is sent to ensure the crane stops in time, avoiding collisions with the maintenance crane and ensuring the safe conduct of maintenance operations.

[0052] 4. Post-completion procedures

[0053] Shutdown and Disassembly: After the maintenance work on the crane in the same span is completed, first turn off the power to the laser transmitter 2, controller 4, warning device 5, and brake linkage interface, and disconnect the device from the crane braking system (wireless or wired). Then release the brake locking device of the caster wheel and remove the device from the work site.

[0054] Inspection and Storage: Conduct a comprehensive inspection of the device, checking for any damage or abnormalities in each component. This includes verifying the proper functioning of the laser emitter 2 and receiver, the cleanliness of the filters, and the correctness of the parameters for the controller 4 and the braking linkage interface. Clean the surface of the device of dust and debris, and store it properly in a dry, safe place for future use. If any problems are found, repair or replace the affected parts promptly to ensure the device functions correctly for the next use.

[0055] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A laser-guided safety limit device for the maintenance of a crane spanning the same distance, characterized in that, include: Movable base A laser emitter, which is mounted on the movable base, with its emitting end oriented parallel to the crane's running track; A laser receiver is mounted on the movable base, with its receiving end corresponding to the emitting end of the laser transmitter; A controller is mounted on the movable base, and its signal input terminal is electrically connected to the signal output terminal of the laser receiver. An alarm device is mounted on the movable base, and its control terminal is electrically connected to the signal output terminal of the controller. The braking linkage interface has its input end electrically connected to the signal output end of the controller, and its output end is used to connect to the braking system signal of the mobile crane operating in the same span.

2. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The braking linkage interface is a wireless communication module, which is wirelessly connected to the controller of the crane braking system.

3. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The braking linkage interface is a wired communication port, which is used to connect to the hardware interface of the crane braking system.

4. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The alarm is an audible and visual alarm, which includes a buzzer and a red flashing light.

5. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The alarm device also includes a voice prompt unit, which is electrically connected to the signal output terminal of the controller.

6. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The controller is a microcontroller, which has a pre-set hierarchical control circuit. The hierarchical control circuit is electrically connected to the laser receiver, the warning device, and the braking linkage interface, respectively.

7. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The controller also integrates a Bluetooth communication module, which is used to communicate with external terminal devices.

8. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The laser receiver has a filter at its receiving window.

9. The same-span crane maintenance safety laser limit device according to claim 1, characterized in that, The bottom of the movable base is equipped with casters, and a shock-absorbing spring is provided between the casters and the movable base. The casters are equipped with a brake locking device.

10. A method of using the same-span crane maintenance safety laser limit device as described in any one of claims 1 to 9, characterized in that, Includes the following steps: Step 1: Move the two laser limit devices for crane maintenance as described in any one of claims 1 to 9 to the safety boundaries on both sides of the crane's running track. Step 2: Activate the laser emitter so that its emitting end emits a laser beam along the direction of the crane's running track, and the laser receiver of another crane maintenance safety laser limit device as described in any one of claims 1 to 9 receives the laser beam, forming a laser warning line spanning the maintenance area; Step 3: When the mobile crane operating in the same span moves to the point of blocking the laser beam, the laser receiver receives the signal change and transmits it to the controller; Step 4: The controller controls the alarm to issue an alert based on the received signal; Step 5: The controller sends a control signal to the braking system of the mobile crane through the braking linkage interface, causing the mobile crane to decelerate or stop.

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