Intelligent safety management and control device and method suitable for magnetic attraction program control driving

Abstract

The invention belongs to the technical field of metal plate cutting, and particularly relates to an intelligent safety management and control device and method suitable for a magnetic-attraction program-controlled traveling crane, and the intelligent safety management and control device comprises a program-controlled traveling crane body and a lifting appliance mounted on the program-controlled traveling crane body; the lifting appliance is connected with a lifting shaft of the program-controlled travelling crane body through a switching structure and serves as a mechanical bearing structure and a mounting platform of the intelligent sensing system and the intelligent execution system; the intelligent sensing system is mounted on the lifting appliance, and is used for collecting image, thickness, weight and contact state data of a target steel plate before and in the grabbing process of the steel plate, and transmitting the data to the upper-layer system; and the intelligent execution system is in signal connection with the intelligent sensing system and is used for executing deviation correction, magnetic attraction, buffering, swing prevention and impact prevention actions according to data acquired by the intelligent sensing system and instructions of the upper-layer system. According to the invention, the sensing capability, the on-line monitoring capability and the dynamic execution capability are deeply fused, and the safe automatic closed-loop control of the steel plate raw material plate in the transportation process is realized.

Description

Technical Field

[0001] This invention belongs to the field of metal sheet cutting technology, specifically an intelligent safety management device and method suitable for magnetically controlled gantry cranes. Background Technology

[0002] Currently, the steel structure plate cutting process generally suffers from prominent problems such as over-reliance on manual experience, difficulty in quality control, and insufficient production line flexibility. Traditional steel raw material plates, transported by ordinary cranes, rely heavily on manual operation and semi-automated machinery. Operators must use tools suspended by the crane to position the raw steel plates, resulting in poor positioning accuracy, low efficiency, and low safety – problems that many steel structure manufacturers urgently need to solve.

[0003] To overcome the challenges of lifting traditional raw steel plates, the manufacturing industry has successively introduced various technological improvement solutions, including the application of programmable cranes, customized lifting tools, and alignment platforms. However, existing solutions still have the following shortcomings: First, they lack automatic verification functions for the thickness and position of the steel plate before gripping, which can easily lead to gripping errors; second, the magnetic flux during magnetic attraction cannot be intelligently matched according to the steel plate parameters, which can easily result in multiple plates being attracted or insufficient attraction; third, there is a lack of real-time monitoring of the contact state during lifting, making it impossible to detect the risk of detachment in time; and fourth, the various detection and control functions are independent of each other, failing to form a systematic closed-loop management system, making it difficult to achieve truly intelligent and safe lifting. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent safety management and control device and method suitable for magnetically controlled gantry cranes, in order to solve the technical problems of reliance on manual operation, poor positioning accuracy, and low safety in the existing steel plate hoisting process. It realizes visual correction and thickness verification before steel plate grabbing, intelligent matching of magnetic flux and weighing verification during grabbing, and real-time monitoring of contact status and anti-fall protection throughout the transportation process, forming a closed-loop intelligent management and control from task request to demagnetization upon arrival, thereby improving the safety and automation level of steel plate hoisting operations.

[0005] The technical solution adopted by the present invention to achieve the above objectives is: an intelligent safety management and control device suitable for magnetically controlled cranes, comprising: a controlled crane and lifting device, an intelligent sensing system and an intelligent sensing and execution system;

[0006] The programmable crane and lifting device includes: a programmable crane body and a lifting device installed thereon; the lifting device is connected to the lifting shaft of the programmable crane body through a transition structure, and serves as the mechanical load-bearing structure and installation platform for the intelligent sensing system and intelligent execution system.

[0007] The intelligent sensing system is installed on the lifting device and is used to collect images, thickness, weight and contact status data of the target steel plate before and during the gripping process, and transmit the data to the upper system.

[0008] The intelligent execution system is installed on the lifting device and is connected to the intelligent sensing system. It is used to perform correction, magnetic attraction, buffering, anti-swaying and anti-impact actions based on the data collected by the intelligent sensing system and the instructions of the upper system.

[0009] The programmable crane and lifting device includes: a programmable crane transfer beam, a servo correction device, a slewing support bearing, a programmable crane lifting beam, and a cantilever frame;

[0010] The top of the programmable crane transfer beam is fixedly connected to the lifting shaft of the crane body to serve as the mounting base for the entire lifting device; a servo correction device is fixedly installed at one end of the bottom of the programmable crane transfer beam, and a slewing support bearing is arranged diagonally opposite to the servo correction device at the other end of the bottom.

[0011] The top of the overhead crane lifting beam is fixedly connected to the output end of the servo correction device and the rotating part of the slewing support bearing, and is driven by the servo correction device to achieve horizontal rotation and position adjustment.

[0012] The cantilever frame is provided in two sets, symmetrically arranged on both sides of the width direction of the programmable crane hoisting beam. The end of each set of cantilever frames serves as a mounting base, equipped with an online weighing module of the intelligent sensing system, as well as a magnetic buffer module and electromagnet of the intelligent execution system.

[0013] The intelligent sensing system includes: a visual correction system, an intelligent detection system, an online monitoring module, and a security management system;

[0014] The vision correction system includes: a vision drive actuator and a vision recognition system;

[0015] The vision-driven actuator is vertically fixed at the lower middle position of the CNC crane's hoisting beam;

[0016] The visual recognition system is fixed at the lower end of the visual drive actuator and is driven by the visual drive actuator to perform lifting and lowering movements. The visual recognition system is a 3D vision camera, which projects downward to form the vision camera's shooting range, used to acquire images of the target steel plate and perform position correction.

[0017] The intelligent inspection system includes: steel plate inspection sensors, ultrasonic thickness sensors, and an online weighing module;

[0018] The steel plate detection sensor is a proximity switch sensor located on the side of the electromagnet at the end of each cantilever frame, used to detect the contact state between the steel plate and the electromagnet.

[0019] The ultrasonic thickness sensor is fixed to the middle side of the lifting beam of the programmable crane, and the detection direction of the ultrasonic thickness sensor is vertically downward, used to measure the thickness of the steel plate.

[0020] The online weighing module is fixed to the top of the cantilever frame and is used to measure the weight of the steel plate in real time.

[0021] The online monitoring module connects to the various sensors of the intelligent sensing system to collect and upload sensor data to the safety management system in real time.

[0022] The security management system is used to make security judgments and issue control commands based on the collected data.

[0023] The intelligent execution system includes:

[0024] Magnetic actuation components are disposed at the ends of each cantilever frame, and each magnetic actuation component includes:

[0025] The magnetic suction buffer module is located below the online weighing module; the magnetic suction buffer module is equipped with a hollow guide shaft and an elastic buffer element, and an electromagnet for adsorbing steel plates is fixed at the lower end of the hollow guide shaft.

[0026] The magnet controller, electrically connected to the electromagnet, is used to match the initial magnetic flux and secondary full magnetic flux of the electromagnet based on the steel plate parameters analyzed by the upper system.

[0027] A safety control method for an intelligent safety control device suitable for magnetically controlled cranes includes the following steps:

[0028] Step S1: The magnetically attached programmable crane is in a safe position and performs an in-situ judgment, and requests the upper-level system to execute the task;

[0029] Step S2: After the upper-level system issues the task, accept the current task; determine whether the current task type meets the conditions for capturing the programmable crane. If it does, continue execution; otherwise, request the upper-level system to execute the task again and report an error.

[0030] Step S3: The programmable crane calls the corresponding program for the current task to perform visual positioning, image analysis, and correction on the steel raw material plate, and confirms the electromagnet magnetic flux signal; after the visual correction is completed and the magnetic flux signal is confirmed, proceed to step S4.

[0031] Step S4: Perform capture and inspection, and determine online whether the captured target is compliant; if the captured target is compliant, continue to step S5; if it is not compliant, issue an alarm message, wait for manual confirmation, and return to step S3 for re-inspection;

[0032] Step S5: The electromagnet is magnetized to trigger the electromagnetic attraction to execute the designated transportation route task. At the same time, before the steel raw material plate is demagnetized, the monitoring data of the electromagnet and the steel raw material plate are monitored in real time through the intelligent sensing system, which uses material detection, online weighing, and online magnetic flux detection. After the transportation task is completed and the monitoring data is normal, proceed to step S6.

[0033] Step S6: After the task of executing the specified transportation route is completed and demagnetization is successful, the magnetically attached programmable crane sends a completion signal to the upper-level system, returns to the safe position of the programmable crane, and requests the next task.

[0034] Step S3, which involves visually locating the steel raw material plate, analyzing the image, performing correction, and confirming the electromagnet's magnetic flux signal, specifically includes:

[0035] Step S3-1: The vision-driven actuator drives the vision recognition system to descend to the shooting position;

[0036] Step S3-2: The 3D vision camera of the visual recognition system takes pictures of the target steel plate at the designated location and acquires multiple local images;

[0037] Step S3-3: Perform image stitching on the multiple images captured to form a complete image of the steel plate surface;

[0038] Step S3-4: Perform a correction analysis on the complete image after the puzzle is completed to identify the deviation between the current actual position and the theoretical position of the steel plate;

[0039] Step S3-5: Drive the servo correction device to adjust the horizontal position and rotation angle of the lifting device according to the deviation, so that the electromagnet is aligned with the gripping position of the target steel plate;

[0040] Step S3-6: Confirm that the electromagnet magnetic flux signal is in standby mode.

[0041] Step S4 includes the following steps:

[0042] Step S4-1: With the electromagnet unmagnetized, the thickness of the target steel plate is measured using an ultrasonic thickness sensor;

[0043] Step S4-2: Compare the measured thickness value with the steel plate thickness data analyzed by the upper system to determine whether the thickness is within the allowable range;

[0044] Step S4-3: After the thickness inspection is qualified, the electromagnet attracts the steel plate and slowly lifts it;

[0045] Step S4-4: Weigh the gripped steel plate in real time using the online weighing module;

[0046] Step S4-5: Compare the measured weight with the theoretical value given by the upper system to determine whether the weight is within the allowable range;

[0047] Steps S4-6: If the thickness or weight deviation exceeds the preset range, the object being grabbed is determined to be non-compliant, an alarm message is issued, manual confirmation is requested, and the process returns to step S3 for re-inspection.

[0048] Step S5 includes the following steps:

[0049] Step S5-1: The magnet controller matches the magnetic flux of the electromagnet according to the steel plate parameters analyzed by the upper system;

[0050] Step S5-2: Trigger electromagnetic pickup, and the programmed crane begins to execute the designated transportation route task;

[0051] Step S5-3: Before the steel raw material plate is demagnetized, the contact state between the steel plate and the electromagnet is detected by a proximity switch sensor; the online weighing module continuously monitors the weight data; at the same time, the real-time magnetic flux data is continuously monitored by the magnet controller.

[0052] Step S5-4: Upload all monitoring data to the security management system in real time.

[0053] Step S6 specifically includes:

[0054] Step S6-1: After the programmable crane transports the steel plate to the designated target location, it stops moving and prepares to demagnetize, and lowers the lifting device so that the lower surface of the steel plate contacts the target placement surface;

[0055] Step S6-2: After the steel plate is placed stably, the magnet controller completes the demagnetization operation, separating the steel plate from the electromagnet;

[0056] Step S6-3: After confirming that the steel plate and the electromagnet have separated through the proximity switch sensor, the magnetically controlled crane sends a task completion signal to the upper-level system.

[0057] Step S6-4: After feedback is received, the programmable crane lifts the spreader to a safe height;

[0058] Step S6-5: After the lift is completed, return to the preset safe position and request the next task from the upper-level system.

[0059] During the execution of steps S3 to S6, an intelligent anti-fall control mechanism is also included, specifically:

[0060] Step S7-1: Monitor the contact signal of the proximity switch sensor, the weight data of the online weighing module, and the magnetic flux data of the magnet controller in real time;

[0061] Step S7-2: When the contact signal is lost, or the weight or magnetic force is not within the preset range, the system automatically stops the vehicle movement; keeps the current magnetic flux of the electromagnet unchanged, prevents automatic demagnetization, and triggers an alarm;

[0062] Step S7-3: Record abnormal data and generate an abnormal event report. After manual confirmation of safety, the alarm is deactivated, and the corresponding steps are returned to be re-executed based on the location of the abnormality.

[0063] The present invention has the following beneficial effects and advantages:

[0064] 1. This invention deeply integrates sensing capabilities, online monitoring capabilities, and dynamic execution capabilities, integrating multiple online monitoring functions into an intelligent programmable crane to achieve safe and automatic closed-loop control of steel plate raw materials during transportation.

[0065] 2. This invention integrates functions such as visual position correction, thickness detection, weighing verification, intelligent magnetic flux matching, and contact status monitoring into one, forming a complete closed-loop control process from task request, pre-grab detection, grab execution, transportation monitoring to demagnetization upon arrival, enabling steel plate hoisting operations to move from single control to system integration innovation.

[0066] 3. This invention uses a 3D vision camera to acquire and correct images of the target steel plate, ensuring that the electromagnet is precisely aligned with the gripping position; it uses an ultrasonic thickness sensor to measure and compare the thickness of the steel plate, avoiding gripping the wrong plate; and it uses an online weighing module to verify the gripping weight in real time, effectively preventing multiple plates from being adsorbed and ensuring single-plate gripping.

[0067] 4. The magnet controller of the present invention matches the initial magnetic flux and secondary full magnetic flux of the electromagnet according to the parameters such as the material and thickness of the steel plate analyzed by the upper system, which not only ensures the effective adsorption of a single steel plate, but also reduces the magnetization effect on the lower steel plate and protects the integrity of the material pile.

[0068] 5. Throughout the hoisting process, this invention continuously monitors the contact status of each magnetic attraction point through proximity switch sensors. Combined with the weight and magnetic flux data from the online weighing module and magnet controller, a multi-dimensional safety monitoring parameter set is constructed. Once an abnormality is detected, the anti-fall program is immediately triggered, stopping the crane movement and maintaining the magnetic flux, effectively preventing steel plate falling accidents. Attached Figure Description

[0069] Figure 1 This is a schematic diagram of the integrated security management and online monitoring system of the present invention;

[0070] Figure 2 This is a flowchart illustrating the intelligent magnetic suction programmable crane execution and detection process of the present invention;

[0071] Figure 3This is a front view of the programmable crane and lifting device of the present invention;

[0072] Figure 4 This is a top view of the programmable crane and lifting device of the present invention;

[0073] Figure 5 This is a side view of the programmable crane and lifting device of the present invention.

[0074] In the diagram: 1 is the transfer beam of the programmable crane; 2 is the servo correction device; 3 is the hoisting beam of the programmable crane; 4 is the vision-driven actuator; 5 is the vision recognition system; 6 is the shooting range of the vision camera; 7 is the ultrasonic thickness sensor; 8 is the online weighing module; 9 is the magnetic buffer module; 10 is the electromagnet; 11 is the proximity switch; 12 is the state of the steel raw material plate when it is magnetically grasped; 13 is the state of the steel raw material plate before it is grasped. Detailed Implementation

[0075] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0076] like Figure 1 As shown, the present invention provides an intelligent safety management and control device suitable for magnetically controlled cranes. Its integrated safety management and online monitoring system includes an intelligent sensing system and an intelligent execution system. The intelligent sensing system is equipped with a visual correction system, an intelligent detection system, and a safety management and control system; the intelligent execution system is equipped with intelligent magnetic flux matching, intelligent anti-sway, and intelligent anti-impact systems.

[0077] like Figure 2 As shown, the intelligent magnetic suction programmable crane execution and detection process of the present invention includes:

[0078] Step ① Magnetic attraction programmable crane safety position determination, i.e., in-situ determination;

[0079] Step 2: Request the upper-level system to execute the task; the upper-level system is an ERP system or MES system, which is used to receive the request signal and approve whether to issue the task instruction;

[0080] Step 3: The upper-level system receives the current task after issuing the task;

[0081] Step 4: Determine whether the current task type meets the conditions for capturing the controlled crane movement;

[0082] Step 5: The programmable crane calls the corresponding program for the current task to perform visual positioning, image analysis, and correction, and confirms the electromagnetic flux signal.

[0083] Step 6: Perform capture and inspection, and determine online whether the captured target is compliant;

[0084] Step 7: The electromagnet is magnetized to trigger electromagnetic attraction to execute the designated transportation path task, while the sensing system monitors the data in real time.

[0085] Step 8: The task of executing the specified transportation route is completed and demagnetization is successful. A completion signal is sent back to the upper-level system.

[0086] Step 9: Return to the safe position of the programmed train and request the next task.

[0087] like Figure 3 , Figure 4 , Figure 5 As shown, the magnetic suction programmable crane lifting device of the present invention includes: programmable crane transfer beam 1, servo correction device 2, slewing support bearing, programmable crane lifting beam 3, vision drive actuator 4, vision recognition system 5, ultrasonic thickness sensor 7, online weighing module 8, magnetic suction buffer module 9, electromagnet 10, proximity switch sensor 11, and cantilever frame.

[0088] The top of the programmable crane transfer beam 1 is fixedly connected to the lifting shaft of the crane body, serving as the mounting base for the entire lifting device. A servo correction device 2 is fixedly installed at one end of the bottom of the programmable crane transfer beam 1, and a slewing support bearing is arranged diagonally opposite to the servo correction device 2 at the other end of the bottom.

[0089] The top of the overhead crane lifting beam 3 is fixedly connected to the output end of the servo correction device 2 and the rotating part of the slewing support bearing, respectively, and is driven by the servo correction device 2 to achieve horizontal rotation and position adjustment.

[0090] Two sets of cantilever frames are symmetrically arranged on both sides of the width direction of the programmable crane hoisting beam 3. The end of each set of cantilever frames serves as the installation base, and is equipped with an online weighing module 8 of the intelligent sensing system, as well as a magnetic buffer module 9 and an electromagnet 10 of the intelligent execution system.

[0091] The vision-driven actuator 4 is vertically fixed at the lower middle position of the overhead crane lifting beam 3. The vision recognition system 5 is fixed at the lower end of the vision-driven actuator 4 and is driven by the vision-driven actuator 4 to perform lifting and lowering movements. The vision recognition system 5 is a 3D vision camera, which projects downward to form the vision camera's shooting range 6, used to acquire images of the target steel plate and perform position correction.

[0092] The ultrasonic thickness sensor 7 is fixed to the middle side of the lifting beam 3 of the programmable crane, with the detection direction vertically downward, and is used to measure the thickness of the steel plate.

[0093] The proximity switch sensor 11 is located on the side of the electromagnet 10 at the end of each cantilever frame to detect the contact state between the steel plate and the electromagnet.

[0094] The online weighing module 8 is fixed to the top of the cantilever frame and is used to measure the weight of the steel plate in real time.

[0095] The magnetic buffer module 9 is located below the online weighing module 8. It has a hollow guide shaft and an elastic buffer element inside, which are used to provide buffer when the electromagnet 10 contacts the steel plate and to apply an auxiliary clamping force after adsorption.

[0096] Electromagnet 10 is fixed to the lower end of the hollow guide shaft of magnetic suction buffer module 9 and is used to attract steel plates.

[0097] The magnet controller is electrically connected to the electromagnet 10 and is used to match the initial magnetic flux and secondary full magnetic flux of the electromagnet 10 according to the steel plate parameters analyzed by the industrial control system.

[0098] The online monitoring module connects to the various sensors of the intelligent sensing system to collect and upload sensor data to the safety management system in real time. The safety management system then uses the collected data to make safety judgments and issue control commands.

[0099] The figure also shows the steel raw material sheet in state 12 during magnetic grasping and state 13 before grasping.

[0100] The intelligent safety management method using the above-mentioned device includes the following steps:

[0101] Step S1: The magnetically attached programmable crane is in a safe position and performs an in-situ judgment, and requests the industrial control system to execute the task.

[0102] Step S2: After the industrial control system issues a task, it accepts the current task; it determines whether the current task type meets the conditions for capturing the programmable crane. If it does, it continues to execute; if it does not, it re-requests the industrial control system to execute the task and reports an error.

[0103] Step S3: The programmable crane calls the corresponding program for the current task to perform visual positioning, image analysis, and correction on the steel raw material plate, and confirms the electromagnet magnetic flux signal. Specifically, this includes: the vision drive actuator 4 drives the vision recognition system 5 to descend to the shooting position; the 3D vision camera of the vision recognition system 5 takes pictures of the target steel plate at the designated position, acquiring multiple partial images; the multiple images are stitched together to form a complete image of the steel plate surface; the complete image after stitching is analyzed for correction to identify the deviation between the actual position and the theoretical position of the steel plate; based on the deviation, the servo correction device 2 is driven to adjust the horizontal position and rotation angle of the lifting device, so that the electromagnet 10 is aligned with the gripping position of the target steel plate; the electromagnet magnetic flux signal is confirmed to be in standby mode. After the visual correction is completed and the magnetic flux signal is confirmed, proceed to step S4.

[0104] Step S4: Perform grasping and detection, and determine online whether the grasped object is compliant. Specifically, this includes: with the electromagnet 10 unmagnetized, using the ultrasonic thickness sensor 7 to detect the thickness of the target steel plate; comparing the measured thickness value with the steel plate thickness data parsed by the industrial control system to determine if the thickness is within the allowable range; after the thickness detection is qualified, the electromagnet 10 attracts the steel plate and slowly lifts it; the grasped steel plate is weighed in real time using the online weighing module 8; the measured weight is compared with the theoretical value given by the industrial control system to determine if the weight is within the allowable range; if the thickness deviation or weight deviation exceeds the preset range, the grasped object is determined to be non-compliant, an alarm message is issued awaiting manual confirmation, and the process returns to step S3 for re-detection. If the grasped object is compliant, proceed to step S5.

[0105] Step S5: The electromagnet is magnetized, triggering electromagnetic attraction to execute the designated transportation route. Simultaneously, before the steel raw material plate is demagnetized, the intelligent sensing system monitors the data of the electromagnet and the steel raw material plate in real time. Specifically, this includes: the magnet controller matching the magnetic flux of electromagnet 10 according to the steel plate parameters analyzed by the industrial control system; triggering electromagnetic attraction, and the programmed crane starting to execute the designated transportation route; before the steel raw material plate is demagnetized, the proximity switch sensor 11 detects the contact state between the steel plate and electromagnet 10; the online weighing module 8 continuously monitors the weight data; the magnet controller continuously monitors the real-time magnetic flux data; and all monitoring data is uploaded to the safety management system in real time. After the transportation task is completed and the monitoring data is normal, proceed to step S6.

[0106] Step S6: After successfully completing the task along the designated transportation route and demagnetizing the steel plate, the magnetically controlled gantry crane sends a completion signal to the industrial control system, returns to its safe position, and requests the next task. Specifically, this includes: after transporting the steel plate to the designated target location, the gantry crane stops moving and prepares for demagnetization; lowering the lifting device so that the lower surface of the steel plate contacts the target placement surface; once the steel plate is placed stably, the magnet controller completes the demagnetization operation, separating the steel plate from the electromagnet 10; after confirming the separation of the steel plate from the electromagnet 10 via the proximity switch sensor 11, the magnetically controlled gantry crane sends a task completion signal to the industrial control system; after receiving the signal, the gantry crane raises the lifting device to a safe height; once raised to the correct position, it returns to the preset safe position and requests the next task from the industrial control system.

[0107] Throughout the execution of steps S3 to S6, an intelligent anti-fall control mechanism is also included: real-time monitoring of the contact signal of the proximity switch sensor 11, the weight data of the online weighing module 8, and the magnetic flux data of the magnet controller; when a loss of contact signal, abnormal weight, or abnormal magnetic flux is detected, the system automatically stops the vehicle movement; the current magnetic flux of the electromagnet 10 remains unchanged, and automatic demagnetization is prohibited; an alarm is triggered; abnormal data is recorded and an abnormal event report is generated; after manual confirmation of safety, the alarm is deactivated, and the corresponding steps are returned to be re-executed based on the location of the abnormality.

[0108] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. The present invention deeply integrates a visual correction system, an intelligent detection system, and an intelligent execution system to construct a closed-loop intelligent control system covering the entire process from task request, pre-grab detection, grab execution, transportation monitoring to demagnetization upon arrival. This technical solution not only achieves multi-dimensional collaboration in position correction, thickness verification, weighing verification, magnetic flux matching, and contact status monitoring during steel plate hoisting, but also realizes automatic identification and safe braking of abnormal working conditions through an intelligent anti-fall program control mechanism. This fundamentally solves the problem of excessive reliance on manual experience in traditional steel plate hoisting operations, significantly improving the safety, accuracy, and automation level of the hoisting process. Simultaneously, real-time recording and traceability of the entire process data provides reliable data support for production management, powerfully promoting the steel structure material cutting industry towards intelligent and unmanned operation. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0109] Those skilled in the art will understand that the above description is merely a preferred embodiment of the present invention, and the features described in the various embodiments and / or claims of this disclosure can be combined or combined in various ways, even if such combinations or combinations are not explicitly described in this disclosure. This is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0110] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention. Clearly, those skilled in the art can make various alterations and modifications to the invention without departing from its spirit and scope. Thus, if these modifications and modifications of the invention fall within the scope of the claims and their equivalents, the invention is also intended to include these modifications and modifications.

Claims

1. An intelligent safety control device suitable for magnetically controlled cranes, characterized in that, include: Programmable crane and lifting device, intelligent sensing system and intelligent sensing execution system; The programmable crane and lifting device includes: a programmable crane body and a lifting device installed thereon; The lifting device is connected to the lifting shaft of the programmable crane body through a transition structure, serving as the mechanical load-bearing structure and installation platform for the intelligent sensing system and intelligent execution system; The intelligent sensing system is installed on the lifting device and is used to collect images, thickness, weight and contact status data of the target steel plate before and during the gripping process, and transmit the data to the upper system. The intelligent execution system is installed on the lifting device and is connected to the intelligent sensing system. It is used to perform correction, magnetic attraction, buffering, anti-swaying and anti-impact actions based on the data collected by the intelligent sensing system and the instructions of the upper system.

2. The intelligent safety control device for magnetically controlled cranes according to claim 1, characterized in that, The programmable crane and lifting device includes: a programmable crane transfer beam (1), a servo correction device (2), a slewing support bearing, a programmable crane lifting beam (3), and a cantilever frame; The top of the programmable crane transfer beam (1) is fixedly connected to the lifting shaft of the crane body to serve as the mounting base for the entire lifting device; a servo correction device (2) is fixedly provided at one end of the bottom of the programmable crane transfer beam (1), and a slewing support bearing is provided at the other end of the bottom, which is diagonally arranged with the servo correction device (2). The top of the programmable crane hoisting beam (3) is fixedly connected to the output end of the servo correction device (2) and the rotating part of the slewing support bearing, respectively, and is driven by the servo correction device (2) to achieve horizontal rotation and position adjustment. The cantilever frame is provided in two sets, symmetrically arranged on both sides of the width direction of the programmable crane hoisting beam (3). The end of each set of cantilever frames serves as the installation base, and is equipped with an online weighing module (8) of the intelligent sensing system, as well as a magnetic buffer module (9) and an electromagnet (10) of the intelligent execution system.

3. The intelligent safety control device for magnetically controlled cranes according to claim 1, characterized in that, The intelligent sensing system includes: a visual correction system, an intelligent detection system, an online monitoring module, and a security management system; The visual correction system includes: a visual drive actuator (4) and a visual recognition system (5). The vision-driven actuator (4) is vertically fixed at the lower middle position of the programmable crane hoisting beam (3); The visual recognition system (5) is fixed at the lower end of the visual drive actuator (4) and is driven by the visual drive actuator (4) to perform lifting and lowering movements. The visual recognition system (5) is a 3D visual camera, which projects downward to form the visual camera shooting range (6) for acquiring images of the target steel plate and performing position correction. The intelligent inspection system includes: a steel plate inspection sensor, an ultrasonic thickness sensor (7), and an online weighing module (8). The steel plate detection sensor is a proximity switch sensor (11) located on the side of the electromagnet (10) at the end of each cantilever frame, used to detect the contact state between the steel plate and the electromagnet. The ultrasonic thickness sensor (7) is fixed on the middle side of the crane beam (3) of the programmable crane, and the detection direction of the ultrasonic thickness sensor (7) is vertically downward, used to measure the thickness of the steel plate. The online weighing module (8) is fixed to the top of the cantilever frame and is used to measure the weight of the steel plate in real time. The online monitoring module connects to the various sensors of the intelligent sensing system to collect and upload sensor data to the safety management system in real time. The security management system is used to make security judgments and issue control commands based on the collected data.

4. The intelligent safety control device for magnetically controlled cranes according to claim 1, characterized in that, The intelligent execution system includes: Magnetic actuation components are disposed at the ends of each cantilever frame, and each magnetic actuation component includes: The magnetic buffer module (9) is located below the online weighing module (8); the magnetic buffer module (9) is provided with a hollow guide shaft and an elastic buffer element, and an electromagnet (10) for adsorbing steel plates is fixed at the lower end of the hollow guide shaft. A magnet controller, electrically connected to an electromagnet (10), is used to match the initial magnetic flux and the second full magnetic flux of the electromagnet (10) based on the steel plate parameters analyzed by the upper system.

5. A safety control method for an intelligent safety control device applicable to magnetically operated controlled vehicles according to any one of claims 1-4, characterized in that, Includes the following steps: Step S1: The magnetically attached programmable crane is in a safe position and performs an in-situ judgment, and requests the upper-level system to execute the task; Step S2: After the upper-level system issues the task, accept the current task; determine whether the current task type meets the conditions for capturing the programmable crane. If it does, continue execution; otherwise, request the upper-level system to execute the task again and report an error. Step S3: The programmable crane calls the corresponding program for the current task to perform visual positioning, image analysis, and correction on the steel raw material plate, and confirms the electromagnet magnetic flux signal; after the visual correction is completed and the magnetic flux signal is confirmed, proceed to step S4. Step S4: Perform capture and inspection, and determine online whether the captured target is compliant; if the captured target is compliant, continue to step S5; if it is not compliant, issue an alarm message, wait for manual confirmation, and return to step S3 for re-inspection; Step S5: The electromagnet is magnetized to trigger the electromagnetic attraction to execute the designated transportation route task. At the same time, before the steel raw material plate is demagnetized, the monitoring data of the electromagnet and the steel raw material plate are monitored in real time through the intelligent sensing system, which uses material detection, online weighing, and online magnetic flux detection. After the transportation task is completed and the monitoring data is normal, proceed to step S6. Step S6: After the task of executing the specified transportation route is completed and demagnetization is successful, the magnetically attached programmable crane sends a completion signal to the upper-level system, returns to the safe position of the programmable crane, and requests the next task.

6. The safety control method for an intelligent safety control device suitable for magnetically controlled cranes according to claim 5, characterized in that, Step S3, which involves visually locating the steel raw material plate, analyzing the image, performing correction, and confirming the electromagnet's magnetic flux signal, specifically includes: Step S3-1: The vision-driven actuator (4) drives the vision recognition system (5) to descend to the shooting position; Step S3-2: The 3D vision camera of the visual recognition system (5) takes pictures of the target steel plate at the designated position and acquires multiple local images; Step S3-3: Perform image stitching on the multiple images captured to form a complete image of the steel plate surface; Step S3-4: Perform a correction analysis on the complete image after the puzzle is completed to identify the deviation between the current actual position and the theoretical position of the steel plate; Step S3-5: Drive the servo correction device (2) according to the deviation to adjust the horizontal position and rotation angle of the lifting device so that the electromagnet (10) is aligned with the gripping position of the target steel plate; Step S3-6: Confirm that the electromagnet magnetic flux signal is in standby mode.

7. The safety control method for an intelligent safety control device suitable for magnetically controlled cranes according to claim 5, characterized in that, Step S4 includes the following steps: Step S4-1: With the electromagnet (10) unmagnetized, the thickness of the target steel plate is detected by the ultrasonic thickness sensor (7); Step S4-2: Compare the measured thickness value with the steel plate thickness data analyzed by the upper system to determine whether the thickness is within the allowable range; Step S4-3: After the thickness test is qualified, the electromagnet (10) attracts the steel plate and slowly lifts it; Step S4-4: Weigh the gripped steel plate in real time using the online weighing module (8); Step S4-5: Compare the measured weight with the theoretical value given by the upper system to determine whether the weight is within the allowable range; Steps S4-6: If the thickness or weight deviation exceeds the preset range, the object being grabbed is determined to be non-compliant, an alarm message is issued, manual confirmation is requested, and the process returns to step S3 for re-inspection.

8. The safety control method for an intelligent safety control device suitable for magnetically controlled cranes according to claim 5, characterized in that, Step S5 includes the following steps: Step S5-1: The magnet controller matches the magnetic flux of the electromagnet (10) according to the steel plate parameters analyzed by the upper system; Step S5-2: Trigger electromagnetic pickup, and the programmed crane begins to execute the designated transportation route task; Step S5-3: Before the steel raw material plate is demagnetized, the contact state between the steel plate and the electromagnet (10) is detected by the proximity switch sensor (11); the online weighing module (8) continuously monitors the weight data; at the same time, the real-time magnetic flux data is continuously monitored by the magnet controller. Step S5-4: Upload all monitoring data to the security management system in real time.

9. The safety control method for an intelligent safety control device suitable for magnetically controlled cranes according to claim 5, characterized in that, Step S6 specifically includes: Step S6-1: After the programmable crane transports the steel plate to the designated target location, it stops moving and prepares to demagnetize, and lowers the lifting device so that the lower surface of the steel plate contacts the target placement surface; Step S6-2: After the steel plate is placed stably, the magnet controller completes the demagnetization operation, so that the steel plate is separated from the electromagnet (10); Step S6-3: After confirming that the steel plate and the electromagnet (10) have been separated by the proximity switch sensor (11), the magnetically controlled crane sends a task completion signal to the upper-level system. Step S6-4: After feedback is received, the programmable crane lifts the spreader to a safe height; Step S6-5: After the lift is completed, return to the preset safe position and request the next task from the upper-level system.

10. A safety control method for an intelligent safety control device applicable to magnetically operated motorized cranes according to any one of claims 5-9, characterized in that, During the execution of steps S3 to S6, an intelligent anti-fall control mechanism is also included, specifically: Step S7-1: Real-time monitoring of the contact signal of the proximity switch sensor (11), the weight data of the online weighing module (8), and the magnetic flux data of the magnet controller; Step S7-2: When the contact signal is lost, or the weight or magnetic force is not within the preset range, the system automatically stops the vehicle movement; keeps the current magnetic flux of the electromagnet (10) unchanged, prevents automatic demagnetization, and triggers an alarm; Step S7-3: Record abnormal data and generate an abnormal event report. After manual confirmation of safety, the alarm is deactivated, and the corresponding steps are returned to be re-executed based on the location of the abnormality.

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