Intelligent hoisting structure of mechanical electrical automation equipment

Abstract

The invention belongs to the technical field of hoisting equipment, and particularly relates to an intelligent hoisting structure of mechanical electrical automation equipment, which comprises a chassis frame, a rotation driving mechanism, a translation assembly and a sling assembly, the chassis frame is connected with an arranged lower stand column through the rotation driving mechanism, the translation assembly is arranged between the lower stand column and an upper stand column, and the sling assembly is connected with the chassis frame through the rotation driving mechanism. A lifting adjusting mechanism matched with the lifting appliance assembly is arranged on the upper side of the upper stand column. According to the invention, a passive gravity center self-adaptive mechanism in which an inclined slide rail is matched with an inclined slide block is designed in the lifting appliance assembly. After the lifting appliance is connected with lifted equipment, the inclined sliding block automatically slides to the gravity center position of the system under the driving of a gravity component, so that a lifting point is accurately overlapped with the gravity center, and sliding impact is absorbed by the hydraulic buffer. The structure does not need complex transmission parts such as a motor lead screw and closed-loop control, and has the remarkable advantages of being simple in structure, high in reliability and low in maintenance cost.

Description

Technical Field

[0001] This invention belongs to the field of hoisting equipment technology, specifically relating to an intelligent hoisting structure for mechanical and electrical automation equipment. Background Technology

[0002] Currently, in the installation and handling of mechanical and electrical automation equipment, balance cranes are widely used as an important auxiliary device. Common pneumatic or mechanical balance cranes achieve load balancing through pneumatic or spring mechanisms, allowing operators to lift and move heavy objects with relatively little force. However, when dealing with irregularly shaped electrical equipment such as large distribution cabinets and precision transformers, the traditional single-point rigid hook is difficult to adapt to the shift in the center of gravity due to the irregular shape and variable center of gravity of the equipment. This can easily cause the equipment to tilt during the lifting process, which not only increases the installation difficulty but may also damage the equipment shell and internal precision components. At the same time, under manual operation, the heavy object is prone to swinging in the air due to inertia, resulting in generally low positioning accuracy. Especially in confined spaces or precision installation scenarios, the positioning error is large, which seriously affects installation efficiency and safety.

[0003] In recent years, some patented technologies have proposed intelligent improvement solutions to address the aforementioned problems. For example, Chinese invention patent CN106429803A discloses an automatic tilting intelligent lifting device that uses a cross-leveling frame in conjunction with a screw drive mechanism to achieve automatic leveling and has anti-sway and precise positioning functions. Chinese invention patent CN111268549B discloses a two-point self-balancing suspension device that automatically adjusts the position of the suspension points on the suspension beam to achieve self-balancing through a position adjuster. The above technical solutions all use active adjustment mechanisms such as motor-driven screws or electric push rods. Although they have solved the problems of center of gravity adjustment and anti-sway to a certain extent, they still have the following shortcomings: First, active adjustment mechanisms require complex transmission systems, sensors, and control algorithms, resulting in complex structures, high manufacturing costs, and wear and tear on components such as lead screw transmission mechanisms after long-term use, affecting adjustment accuracy and reliability. In particular, there is a lack of passive center of gravity adjustment structures that can utilize gravity for self-drive without the need for an external power source. Secondly, the existing patented technologies for anti-sway control are mostly functional descriptions, lacking specific multi-sensor fusion schemes and control parameters, making them difficult to apply directly to practical engineering applications and unable to achieve accurate prediction and active suppression of the swaying posture of the spreader. Third, the chassis of existing mobile hoisting equipment mostly adopts a fixed support structure, which cannot automatically level itself according to ground conditions. It has poor stability when operating on complex ground, and there is a risk of overturning. In addition, it lacks the function of real-time calculation and early warning of the overturning moment of the whole machine.

[0004] To address these issues, this invention proposes an intelligent hoisting structure for mechanical and electrical automation equipment. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent hoisting structure for mechanical and electrical automation equipment, which can solve the above-mentioned technical problems.

[0006] The specific technical solution adopted by this invention is as follows: The present invention provides an intelligent hoisting structure for mechanical and electrical automation equipment, including a chassis frame, a rotary drive mechanism, a translation assembly and a hoisting assembly. The chassis frame is connected to a lower column through the rotary drive mechanism. The translation assembly is located between the lower column and the upper column. The upper side of the upper column is provided with a lifting adjustment mechanism that cooperates with the hoisting assembly. Hydraulic support legs are detachably installed at the four corners of the chassis frame. Balance sensors are installed on the hydraulic support legs. Moving wheels are installed at the four corners of the bottom surface of the chassis frame, offset from the hydraulic support legs. Dual-axis tilt sensors are installed on the chassis frame. A controller that is misaligned with the rotary drive mechanism is mounted on the chassis frame.

[0007] Preferably, the translation assembly includes a lower stabilizer, an upper stabilizer, a lead screw, and a translation drive motor. The lower stabilizer is installed at the upper end of the lower column, and the upper stabilizer is installed at the lower end of the upper column and located above the lower stabilizer. Translation slide rails are detachably installed on both sides of the surface of the lower stabilizer, and translation sliders are detachably installed on both sides of the bottom surface of the upper stabilizer. The translation sliders slide in cooperation with the translation slide rails. The two sides of the lead screw are detachably mounted on the surface of the lower stabilizer via bearing seats and are located between two translation slide rails. One side of the lead screw is connected to the output shaft of the translation drive motor via a coupling. The translation drive motor is detachably mounted on the surface of the lower stabilizer. A synchronization plate is provided on the bottom surface of the upper stabilizer. A screw hole seat that mates with the lead screw is installed on the synchronization plate. A translation sensor is provided between the lead screw and one of the translation slide rails. The translation sensor is installed on the surface of the lower stabilizer. The detection element on the translation sensor is installed on the synchronization plate.

[0008] Preferably, the rotary drive mechanism includes a slewing bearing, a drive gear, and a slewing drive motor. The inner ring of the slewing bearing is bolted to the chassis frame. A mounting plate is provided above the slewing bearing and is located on the lower side of the lower column. The mounting plate is bolted to the outer ring of the slewing bearing. A rotary encoder corresponding to the center of the slewing bearing is installed on the chassis frame, and the rotary encoder is linked to the mounting plate. The drive gear meshes with the outer gear ring of the slewing bearing. The drive gear is mounted on the output shaft of the slewing drive motor. The slewing drive motor is detachably mounted on the mounting bracket, which is mounted on the chassis frame.

[0009] Preferably, the lifting adjustment mechanism includes a main boom, a winch, and a luffing cylinder. One side of the main boom is hinged to an upper column. The winch is detachably mounted on the upper end of the upper column. A lifting wire is wound on the winch. The free end of the lifting wire is located on the bottom surface of the other end of the main boom. The lower side of the lifting wire is connected to the lifting device assembly. A fixed pulley is installed on the side of the other end of the main boom. The fixed pulley rotates in cooperation with the lifting wire through an alternating rope threading method. The luffing cylinder is located below the main boom, with its fixed end mounted on the upper column via a hinged seat, and its telescopic end mounted on the middle of the bottom surface of the main boom via a hinged seat.

[0010] Preferably, the lifting assembly includes a movable pulley, an inclined frame, a synchronous frame, and a mounting frame. The movable pulley is located below the main boom and rolls in cooperation with the lifting wire through an alternating rope threading method. The inclined frame is located below the movable pulley and is bolted to it. The inclined frame is equipped with a center of gravity adjustment mechanism. The synchronization frame is located below and connected to the center of gravity adjustment mechanism. The bottom surface of the synchronization frame is provided with a hinge seat that is connected to the upper side of the mounting frame. A suspension tension sensor is provided on the hinge seat. An end effector is detachably installed on the mounting frame.

[0011] Preferably, the center of gravity adjustment mechanism includes an inclined slide rail, an inclined slider, and two hydraulic dampers. The inclined slide rail is detachably mounted on the bottom surface of the inclined frame, and the inclined slider slides in cooperation with the inclined slide rail. The synchronization frame is disposed on the bottom surface of the inclined slider. Two hydraulic dampers are symmetrically arranged on opposite sides of the tilting frame, and the telescopic ends of the two hydraulic dampers are rotatably mounted on both sides of the synchronization frame; symmetrical fixed frames are provided on the other opposite side of the tilting frame; the fixed ends of the two hydraulic dampers are rotatably mounted on the two fixed frames respectively.

[0012] Preferably, the tilting frame and tilting slide rail are arranged at an angle of 5-15° along the length direction.

[0013] Preferably, the movable pulley is equipped with a lifting tension sensor and a wireless tilt sensor; The end effector includes at least one of a hydraulic adaptive clamp, an electromagnetic chuck array, or a pallet-type lifting device.

[0014] Preferably, the controller is a PLC controller, which is electrically connected to the drive elements of the dual-axis tilt sensor, balance sensor, translation sensor, rotary encoder, lifting tension sensor, wireless tilt sensor, suspension tension sensor, translation drive motor, slewing drive motor, hoisting equipment, solenoid valve of luffing cylinder, and end effector.

[0015] Preferably, the PLC controller is configured to perform the following control steps: Step 1: Read the chassis tilt angle data collected by the dual-axis tilt sensor, and control the hydraulic support legs to extend and retract synchronously until the chassis tilt angle is ≤0.5°; Step 2: Receive the end effector selection command, control the spreader assembly to move above the actuator storage rack, and complete the automatic docking and locking of the end effector; Step 3: Control the end effector to clamp or adsorb the equipment to be lifted, control the hoisting equipment to lift, and monitor the lifting weight through the lifting tension sensor; Step 4: After the control equipment is lifted to 50mm off the ground and suspended, the tilting slider will automatically slide along the tilting rail to the center of gravity position. After the posture is stable, the suspension tension sensor will confirm that the force on each lifting point is balanced. Step 5: Collect data from multiple sensors, and output compensation speed commands to the hoisting equipment and rotary motor through Kalman filtering and fuzzy PID controller to control the swing amplitude within ±3mm; Step 6: Receive the target translation or rotation command, and drive the corresponding motor to move until the target position is reached through real-time feedback from the translation sensor or rotary encoder; Step 7: Control the hoisting equipment to lower, use the laser rangefinder to measure the distance to control deceleration and stop, and control the end effector to release or disengage; Step 8: Control the spreader assembly to reset, retract the hydraulic support legs, and de-energize all actuators to enter standby mode; The PLC controller is also configured to perform at least one of the following safety protection mechanisms: overload protection, overturning warning, and power failure protection.

[0016] The beneficial effects are: I. Passive self-adaptive center of gravity structure To address the problems of complex structure, high cost, and easy wear of existing active adjustment mechanisms, this invention designs a passive center-of-gravity self-adaptive mechanism in the lifting device assembly, consisting of an inclined slide rail and an inclined slider. After the lifting device is connected to the equipment being lifted, the inclined slider automatically slides to the system's center of gravity position under the drive of gravity, achieving precise alignment between the lifting point and the center of gravity, and the sliding impact is absorbed by a hydraulic buffer. This structure eliminates the need for complex transmission components such as motors and lead screws, as well as closed-loop control, offering significant advantages such as simple structure, high reliability, and low maintenance costs.

[0017] II. Multi-sensor fusion anti-sway control system To address the issues of low positioning accuracy and lack of specific solutions for anti-sway control in existing balanced cranes, this invention constructs a multi-source sensing network consisting of a six-axis IMU, laser rangefinder, wireless tilt and tension sensors. The sway state of the lifting device is calculated through Kalman filtering, and parameters are dynamically corrected by a fuzzy PID controller, outputting a compensation speed to the winch and slewing motors. This control strategy achieves a 10ms control cycle, keeping the sway amplitude within ±3mm, achieving a translational positioning accuracy of ±1mm and a rotational accuracy of ±1°, providing reliable assurance for the automated installation of precision electrical equipment.

[0018] III. Automatic chassis leveling and multiple safety protections To address the issues of poor stability and overturning risk in mobile hoisting equipment, this invention incorporates hydraulic support legs and dual-axis tilt sensors in the chassis. The PLC automatically adjusts the synchronous extension and retraction of the support legs based on tilt angle data, achieving rapid leveling within 30 seconds (tilt angle ≤ 0.5°). Simultaneously, it operates a triple safety mechanism: overload protection, overturning moment calculation and early warning, and emergency descent in case of power failure. This forms a complete closed loop from foundation leveling and operation monitoring to emergency handling, effectively ensuring operational safety under complex conditions.

[0019] IV. Modular Quick-Change End Effect System To address the problem of single lifting devices being unable to meet diverse lifting needs and resulting in low operational efficiency, this invention designs a quick-change interface platform consisting of a three-point positioning tapered pin, an automatic locking rotary jaw, and an electro-hydraulic integrated quick-connect mechanism, with a switching time of no more than 30 seconds. It is equipped with three end effectors: a hydraulic clamping clamp, an electromagnetic chuck array, and a pallet-type lifting device, respectively suitable for equipment with bases, precision sheet metal, and packaging boxes without lifting points, achieving multi-purpose functionality and significantly improving equipment utilization and operational efficiency. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is an exploded view of the connection structure between the bottom frame and the lower support column of the present invention; Figure 3 This is a schematic diagram of the explosion distribution structure of the translation assembly of the present invention; Figure 4 This is a schematic diagram of the exploded distribution structure of the lifting device assembly of the present invention; Figure 5 This is a flowchart of the automatic chassis adjustment control system of the present invention; Figure 6 This is a flowchart of the rotation and translation adjustment control of the present invention; Figure 7 This is a flowchart of the lifting control process for the lifting device assembly of the present invention; Figure 8 This is a flowchart of the passive center of gravity automatic adjustment control of the present invention; Figure 9 This is a flowchart of the anti-sway control process of the present invention; Figure 10 This is a flowchart of the overload and abnormal attitude protection control of the present invention; Figure 11 This is a flowchart of the positioning and reset control process of the present invention.

[0021] The attached diagram lists the components represented by each number as follows: 1. Chassis frame; 2. Lower column; 21. Mounting plate; 3. Translation assembly; 31. Lower stabilizer; 32. Upper stabilizer; 32a. Synchronization plate; 33. Translation slide rail; 34. Translation slider; 35. Translation sensor; 36. Lead screw; 37. Translation drive motor; 4. Upper column; 5. Main boom; 51. Fixed pulley; 6. Lifting device assembly; 61. Moving pulley; 61a. Lifting tension sensor; 61b. Wireless tilt sensor; 62. Tilt frame; 62a. Support frame; 63. Tilt 64. Slide rail; 65. Tilt slider; 66. Synchronizing frame; 67. Hinge seat; 68. Suspension tension sensor; 69. Hydraulic buffer; 60. Mounting bracket; 61. End effector; 7. Winch; 8. Hoisting wire; 9. Luffing cylinder; 10. Hydraulic support leg; 10a. Displacement sensor; 11. Moving wheel; 12. Slewing bearing; 13. Rotary encoder; 14. Dual-axis tilt sensor; 15. Drive gear; 16. Slewing drive motor; 17. Fixing frame; 18. Controller. Detailed Implementation

[0022] To make the objectives and advantages of this invention clearer, the invention will be specifically described below with reference to embodiments. It should be understood that the following text is merely used to describe one or more specific embodiments of the invention and does not strictly limit the scope of protection specifically claimed by the invention.

[0023] The present invention describes an intelligent hoisting structure for mechanical and electrical automation equipment, such as... Figure 1 As shown in the diagram (refer to the overall structural schematic), it mainly includes five modules: chassis frame 1, rotary drive mechanism, translation assembly 3, lifting and adjusting mechanism, and lifting device assembly 6. Each module adopts a modular design, which facilitates manufacturing, assembly, and maintenance.

[0024] The chassis frame 1 is constructed from Q355B high-strength rectangular steel pipes welded into an H-shaped frame structure. Hydraulic support legs 10 are detachably mounted at the four corners of the frame via bolts. These hydraulic support legs 10 utilize Rexroth CDT3 series hydraulic cylinders, with built-in displacement sensors 10a and pressure sensors, and a single leg support force of no less than 5 tons. Universal casters 11 are offset on the inner side of the hydraulic support legs 10, using polyurethane-coated wheels with a diameter of 200mm and a single load capacity of 1.5 tons. Each caster 11 has a built-in mechanical locking device. A dual-axis tilt sensor 14, using the KEYENCE GT2 series, is fixed to the geometric center of the chassis frame 1 via a mounting bracket, with a measurement accuracy of ±0.01°, used for real-time detection of chassis levelness. A control cabinet is located at the rear of the chassis frame 1, housing a Siemens S7-1500 series PLC controller 18, a Schneider ATV340 series frequency converter, and a hydraulic station solenoid valve assembly.

[0025] like Figure 2 As shown, the rotary drive mechanism consists of a slewing bearing 12, a drive gear 15, and a rotary drive motor 16. The slewing bearing 12 is a LYC 010 series single-row four-point contact ball bearing. The inner ring is fixedly connected to the chassis frame 1 by 12 M20 high-strength bolts, and the outer ring is fixedly connected to the mounting plate 21 by 12 M20 high-strength bolts. The mounting plate 21 is welded to the bottom of the lower column 2. The rotary drive motor 16 is a SEW R series helical gear reducer motor with a power of 3kW. The output shaft end is equipped with a drive gear 15, which meshes with the outer gear ring of the slewing bearing 12, with a transmission ratio of 1:8. It is mounted on a fixed bracket 17 on the chassis frame 1. A rotary encoder 13, corresponding to the center of the slewing bearing 12, is mounted on the chassis frame 1. A Heidenhain ERN 1387 series encoder is selected, which is linked to the mounting plate 21 via a coupling to achieve real-time closed-loop control of the rotation angle.

[0026] like Figure 3As shown, the translation assembly 3 is positioned between the lower column 2 and the upper column 4. A lower stabilizer 31 is welded to the upper end of the lower column 2. Two translation slide rails 33, using HGW45 series linear guides with a length of 800mm, are bolted to both sides of the lower stabilizer 31. An upper stabilizer 32 is welded to the lower end of the upper column 4. Translation sliders 34, which mate with the translation slide rails 33, are fixed to both sides of the bottom surface of the upper stabilizer 32. A lead screw 36, using THKBNFN series ball screws with a diameter of 32mm and a lead of 10mm, is mounted on the center of the lower stabilizer 31 via two bearing seats. One end of the lead screw 36 is connected to the output shaft of the translation drive motor 37 via a perforated coupling. The translation drive motor 37 is a Mitsubishi HG-KR series servo motor with a power of 1.5kW and an integrated encoder. A synchronization plate 32a is fixed to the bottom surface of the upper stabilizer 32, and a screw hole seat that mates with the lead screw 36 is installed on the synchronization plate 32a. A translation sensor 35 is installed on the surface of the lower stabilizer 31 near the lead screw 36. A Balluff BTL7 series magnetostrictive displacement sensor 10a with a range of 800mm is selected, and the sensing element is installed on the synchronization plate 32a.

[0027] like Figure 1 As shown, the lifting and adjusting mechanism includes a main boom 5, a winch 7, and a luffing cylinder 9. The main boom 5 is a box-beam structure welded from Q355B steel plates, with a cross-sectional dimension of 200×150mm and a wall thickness of 8mm. One end of the main boom 5 is hinged to the upper part of the upper column 4 via a pin. The winch 7 is a Demag DC-Com series electric chain hoist with a rated lifting capacity of 3 tons and a lifting speed of 4 / 1m / min, installed on the top of the upper column 4. A lifting wire 8 is wound on the winch 7. The lifting wire 8 is a φ10mm steel wire rope. The free end passes over the fixed pulley 51 at the other end of the main boom 5 and connects to the movable pulley 61 of the lifting assembly 6, using a four-fold alternating rope threading method. The variable amplitude cylinder 9 is a constant force cylinder HSG series, with a cylinder diameter of 80mm, a rod diameter of 55mm, and a stroke of 600mm. The fixed end of the cylinder is installed in the middle of the upper column 4 through the hinge seat 65a, and the telescopic end is installed in the middle of the bottom surface of the main boom 5 through the hinge seat 65a.

[0028] Detailed Implementation of Lifting Gear Assembly 6 like Figure 1 and Figure 4As shown, the lifting assembly 6 includes a movable pulley 61, an inclined frame 62, a synchronous frame 65, and a mounting frame 67. The movable pulley 61 is a four-wheeled cast steel pulley with a diameter of 200mm, which rolls in conjunction with the lifting wire 8 using an alternating rope threading method. A lifting tension sensor 61a and a wireless tilt sensor 61b are installed on the movable pulley 61. The lifting tension sensor 61a is an S-type tension / compression sensor with a range of 5 tons and an accuracy of 0.5%FS, installed at the connection between the shaft of the movable pulley 61 and the hook. The wireless tilt sensor 61b is a WitMotion WT901 series sensor with a measurement range of ±180° and an accuracy of 0.05°.

[0029] A tilting frame 62 is bolted to the bottom of the movable pulley 61. The tilting frame 62 is made of 6061 aluminum alloy, which is lightweight and high-strength. A tilting rail 63 is arranged on the bottom surface of the tilting frame 62 at a 5-15° angle along its length, preferably 8°. The tilting rail 63 is an MGN15C miniature linear guide, 400mm in length, and is fixed to the tilting frame 62 with bolts. The tilting slider 64 slides in conjunction with the tilting rail 63, and the bottom surface of the slider is fixedly connected to the synchronization frame 65 with bolts.

[0030] The center of gravity adjustment mechanism includes the aforementioned tilting slide rail 63, tilting slider 64, and two hydraulic dampers 66. The hydraulic dampers 66 are selected from the ACE industrial damper MC series, with an adjustable buffer force range of 2000-5000N and a stroke of 100mm. The two hydraulic dampers 66 are symmetrically arranged on opposite sides of the tilting frame 62. The fixed ends of the dampers are rotatably mounted on the support frame 62a via pins, and the support frame 62a is welded to both sides of the tilting frame 62. The telescopic ends of the dampers are rotatably mounted on both sides of the synchronization frame 65 via pins. When the end effector 68 clamps and lifts the equipment, the tilting slider 64 automatically slides along the slide rail to the center of gravity position under the action of gravity, and the hydraulic dampers 66 provide damping to prevent impact.

[0031] The bottom surface of the synchronization frame 65 is connected to the mounting frame 67 via a hinged seat 65a. A suspension tension sensor 65b is mounted on the hinged seat 65a, and an S-type sensor of the same model as the lifting tension sensor 61a is selected. Three types of end effectors 68 are detachably mounted below the mounting frame 67 via a quick-change interface platform: a hydraulic adaptive clamp, an electromagnetic chuck array, and a pallet-type lifting device.

[0032] The hydraulic adaptive clamp consists of a clamp frame, left and right clamping arms, a hydraulic cylinder, and a pressure sensor. The hydraulic cylinder is a Rexroth CDT3 series, with a cylinder diameter of 63mm and a thrust of 2.5 tons, which drives the clamping arms to open and close. The pressure sensor monitors the clamping force in real time.

[0033] The electromagnetic chuck array consists of 6 independently controlled electromagnets, each with an attraction force of 500 kg and a chuck diameter of 120 mm. It adopts a power-off design, relying on permanent magnets to maintain attraction when power is off, ensuring high safety.

[0034] The pallet-type lifting device consists of a rigid pallet and adjustable lifting straps. The pallet size can be customized, and the surface is coated with an anti-slip coating.

[0035] The control system of this invention uses a Siemens S7-1500 PLC as the control core and is programmed and configured using TIA Portal V17, with a control cycle set to 10ms. Figure 5-11 As shown, the system operation steps are as follows: Step 1: System initialization and automatic chassis leveling After the operator moves the equipment to the work position, they initiate the automatic leveling program via wireless remote control. The PLC reads the chassis tilt angle data θx and θy collected by the dual-axis tilt sensor 14 (Keyence GT2), calculates the required extension of each hydraulic support leg 10 (Rexroth CDT3), and controls the hydraulic station to supply oil to the support legs via a proportional valve, causing the support legs to extend and retract synchronously. During this process, the displacement sensor 10a and pressure sensor built into the support legs provide real-time feedback on the extension length and support force, forming a closed-loop control. When the dual-axis tilt sensor 14 detects a tilt angle ≤ 0.5°, leveling is complete, and the PLC records the current status. The entire leveling process takes no more than 30 seconds.

[0036] Step 2: End effector replacement Operators can disassemble and replace different end effectors 68 according to the type of equipment to be hoisted.

[0037] Step 3: Equipment clamping and lifting Operators control the end effector to clamp or attract the suspended equipment via a wireless remote control. If a hydraulic clamp is used, the PLC controls the hydraulic cylinder to drive the clamping arm to close, and the pressure sensor provides feedback on the clamping force. The clamping force stops when it reaches the set value (usually 1.5 times the weight of the equipment). If an electromagnetic chuck array is used, the PLC sequentially energizes 6 sets of electromagnets, and the attraction force can be adjusted in stages according to the weight of the equipment to ensure uniform force distribution. If a pallet-type lifting device is used, the operator manually adjusts the lifting straps and secures the equipment.

[0038] After clamping is completed, the PLC controls the start of the hoisting device 7 (Demag DC-Com), which lifts the equipment through the rolling action of the lifting wire 8 and the moving pulley 61. The lifting tension sensor 61a monitors the lifting weight in real time. If the load exceeds the rated load (3 tons), the PLC immediately cuts off the lifting power and issues an audible and visual alarm.

[0039] Step 4: Passive automatic center of gravity adjustment After the equipment is lifted to approximately 50mm off the ground and suspended, under the influence of gravity, the tilting slider 64 automatically slides along the tilting rail 63 (tilt angle 8°) to the system's center of gravity, aligning the lifting point with the center of gravity. During the sliding process, two hydraulic buffers 66 (ACE MC series) provide gradually increasing damping force to absorb sliding impacts and prevent equipment swaying. The wireless tilt sensor 61b detects the tilt angle of the lifting device in real time. Once the posture is stable (tilt angle change ≤0.1° within 1 second), the PLC confirms that the force on each lifting point is balanced via the suspension tension sensor 65b, and the center of gravity adjustment is complete.

[0040] Step 5: Intelligent Anti-Sway Control During lifting and movement, the PLC continuously runs the anti-sway control program. The system collects multi-sensor data with a 10ms cycle: a six-axis IMU collects the angular velocity ω and acceleration a of the spreader; three laser rangefinders are arranged in an equilateral triangle on the bottom of the spreader to measure the spreader's attitude and relative distance; a wireless tilt sensor 61b detects the spreader's tilt angle θ; and a lifting tension sensor 61a and a suspension tension sensor 65b monitor the lifting weight and tension changes, respectively.

[0041] The PLC employs a Kalman filter algorithm to fuse data from multiple sensors, calculating the swing angle θ_swing and angular velocity ω_swing of the lifting device in real time. The fuzzy PID controller 18 takes E=θ_swing and EC=ω_swing as inputs, dynamically correcting the PID parameters according to a preset fuzzy rule table (e.g., large angle + large speed → large compensation; small angle + small speed → micro compensation), and outputs compensation speed commands to the frequency converters of the hoisting equipment 7 and the rotary motor, achieving active anti-sway suppression. The control objective is to control the swing amplitude within ±3mm.

[0042] Step 6: Translation and Rotation Positioning The operator inputs translation or rotation commands via a wireless remote control. During translation control, the PLC reads the current position collected by the translation sensor 35 (Balluff BTL7), compares it with the target position, and drives the translation drive motor 37 (Mitsubishi HG-KR) to rotate the lead screw 36, causing the upper column 4 to move along the translation slide rail 33. The translation sensor 35 provides real-time position feedback until the target is reached, with a positioning accuracy of ≤±1mm. During rotation control, the PLC reads the current angle collected by the rotary encoder 13 (Heidenhain ERN 1387), drives the rotation drive motor 16 (SEW R series) to rotate the drive gear 15, causing the column to rotate. The rotary encoder 13 provides real-time angle feedback until the target is reached, with a positioning accuracy of ≤±1°.

[0043] Step 7: Precisely position and lower the device, then reset it. After the lifting device carrying the equipment is moved above the installation position, the PLC controls the winch 7 to slowly lower it. A laser rangefinder sensor measures the distance between the lifting device and the lifted equipment or the ground in real time. When the distance is less than 100mm, the winch 7 decelerates; when the distance is less than 10mm, the winch 7 stops. Once the equipment is in place, the PLC controls the end effector 68 to release or disengage.

[0044] After the operation is completed, the PLC controls the lifting device assembly 6 to reset: the end effector 68 returns to the storage rack, the rotating jaws unlock, and the lifting device assembly 6 separates from the end effector 68. The main boom 5 resets to its initial position, and the winch retracts the rope to raise the lifting device to its upper limit. The hydraulic support legs 10 are simultaneously retracted, the moving wheels 11 touch the ground, all actuators are powered off, and the sensors enter a low-power standby mode, awaiting the next operation command.

[0045] The system operates in parallel with triple safety protection: Overload protection: The lifting tension sensor 61a monitors the lifting weight in real time. When the load exceeds 110% of the rated load, the PLC automatically cuts off the lifting power and issues an audible and visual alarm until the load drops to a safe range.

[0046] Overturning warning: The PLC calculates the overturning moment in real time based on the chassis tilt angle collected by the dual-axis tilt sensor 14, the lifting weight collected by the lifting tension sensor 61a, the main boom 5 posture collected by the boom tilt sensor, and the slewing angle collected by the rotary encoder 13. When the overturning moment reaches 80% of the safety threshold, an early warning is issued, and when it reaches 100%, operation in the dangerous direction is automatically restricted.

[0047] Power failure protection: The system is equipped with a backup battery (12V / 100Ah), and the power supply voltage detection module monitors the mains power status in real time. When a power failure is detected, the PLC automatically switches to battery power, starts the emergency descent program, and controls the hoist 7 to slowly reverse, smoothly lowering the heavy object to the ground.

[0048] The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. All standard parts used in this application can be purchased commercially, and can be customized according to the description and drawings. The specific connection methods of each part all adopt conventional methods such as bolts, rivets, and welding, which are mature technologies in the prior art. The machinery, parts, and equipment all adopt conventional models in the prior art. The control method is automatic control through a controller. The control circuit of the controller can be implemented by simple programming by those skilled in the art, and is common knowledge in the field. Furthermore, this application is mainly used to protect mechanical devices, so the control method and circuit connection will not be explained in detail here. Structures, devices, and operating methods not specifically described or explained in this invention, unless otherwise specified or limited, are implemented according to conventional methods in the field and relevant national standards.

Claims

1. An intelligent hoisting structure for mechanical and electrical automation equipment, characterized in that: It includes a chassis frame (1), a rotary drive mechanism, a translation assembly (3) and a lifting assembly (6). The chassis frame (1) is connected to the lower column (2) through the rotary drive mechanism. The translation assembly (3) is located between the lower column (2) and the upper column (4). The upper column (4) is provided with a lifting adjustment mechanism that cooperates with the lifting assembly (6). Hydraulic support legs (10) are detachably installed at the four corners of the chassis frame (1). A balance sensor is provided on the hydraulic support leg (10). Moving wheels (11) are installed at the four corners of the bottom surface of the chassis frame (1) in a staggered manner with the hydraulic support leg (10). A dual-axis tilt sensor (14) is installed on the chassis frame (1). A controller (18) that is misaligned with the rotary drive mechanism is installed on the chassis frame (1).

2. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 1, characterized in that: The translation assembly (3) includes a lower stabilizer (31), an upper stabilizer (32), a lead screw (36), and a translation drive motor (37). The lower stabilizer (31) is installed on the upper end of the lower column (2), and the upper stabilizer (32) is installed on the lower end of the upper column (4) and located above the lower stabilizer (31). Translation slide rails (33) are detachably installed on both sides of the surface of the lower stabilizer (31), and translation sliders (34) are detachably installed on both sides of the bottom surface of the upper stabilizer (32). The translation sliders (34) slide in cooperation with the translation slide rails (33). The two sides of the lead screw (36) are detachably mounted on the surface of the lower stabilizer (31) via bearing seats and located between two translation slide rails (33). One side of the lead screw (36) is connected to the output shaft of the translation drive motor (37) via a coupling. The translation drive motor (37) is detachably mounted on the surface of the lower stabilizer (31). The bottom surface of the upper stabilizer (32) is provided with a synchronization plate (32a). The synchronization plate (32a) is equipped with a screw hole seat that is threaded to the lead screw (36). A translation sensor (35) is provided between the lead screw (36) and one of the translation slide rails (33). The translation sensor (35) is installed on the surface of the lower stabilizer (31). The detection element on the translation sensor (35) is installed on the synchronization plate (32a).

3. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 2, characterized in that: The rotary drive mechanism includes a slewing bearing (12), a drive gear (15), and a rotary drive motor (16). The inner ring of the slewing bearing (12) is bolted to the chassis frame (1). A mounting plate (21) is provided above the slewing bearing (12). The mounting plate (21) is located on the lower side of the lower column (2). The mounting plate (21) is bolted to the outer ring of the slewing bearing (12). A rotary encoder (13) corresponding to the center of the slewing bearing (12) is installed on the chassis frame (1), and the rotary encoder (13) is linked to the mounting plate (21). The drive gear (15) meshes with the outer gear ring of the slewing bearing (12). The drive gear (15) is mounted on the output shaft of the slewing drive motor (16). The slewing drive motor (16) is detachably mounted on the mounting bracket (67). The mounting bracket (67) is mounted on the chassis frame (1).

4. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 1, characterized in that: The lifting and adjusting mechanism includes a main boom (5), a winch (7) and a variable amplitude cylinder (9). One side of the main boom (5) is hinged to the upper column (4). The winch (7) is detachably installed on the upper end of the upper column (4). A lifting wire (8) is wound on the winch (7). The free end of the lifting wire (8) is located on the bottom surface of the other end of the main boom (5). The lower side of the lifting wire (8) is connected to the lifting device assembly (6). A fixed pulley (51) is installed on the side of the other end of the main boom (5). The fixed pulley (51) rolls with the lifting wire (8) by alternating rope threading. The luffing cylinder (9) is located below the main boom (5), and its fixed end is mounted on the upper column (4) via a hinge seat (65a). The telescopic end of the luffing cylinder (9) is mounted on the middle of the bottom surface of the main boom (5) via a hinge seat (65a).

5. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 4, characterized in that: The lifting assembly (6) includes a movable pulley (61), an inclined frame (62), a synchronous frame (65), and a mounting frame (67). The movable pulley (61) is located below the main boom (5) and rolls in cooperation with the lifting wire (8) by alternating rope threading. The inclined frame (62) is located below the movable pulley (61) and is bolted to it. The inclined frame (62) is equipped with a center of gravity adjustment mechanism. The synchronization frame (65) is located below and connected to the center of gravity adjustment mechanism. The bottom surface of the synchronization frame (65) is provided with a hinge seat (65a) connected to the upper side of the mounting frame (67). A suspension tension sensor (65b) is provided on the hinge seat (65a). An end effector (68) is detachably installed on the mounting frame (67).

6. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 5, characterized in that: The center of gravity adjustment mechanism includes an inclined slide rail (63), an inclined slider (64), and two hydraulic buffers (66). The inclined slide rail (63) is detachably mounted on the bottom surface of the inclined frame (62), and the inclined slider (64) slides in cooperation with the inclined slide rail (63). The synchronous frame (65) is set on the bottom surface of the inclined slider (64). Two hydraulic buffers (66) are symmetrically arranged on opposite sides of the tilting frame (62), and the telescopic ends of the two hydraulic buffers (66) are rotatably mounted on both sides of the synchronizing frame (65); symmetrical fixed frames (17) are provided on the other opposite side of the tilting frame (62); the fixed ends of the two hydraulic buffers (66) are rotatably mounted on the two fixed frames (17) respectively.

7. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 6, characterized in that: The tilting frame (62) and the tilting slide rail (63) are arranged at an angle of 5-15° along the length direction.

8. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 5, characterized in that: The movable pulley (61) is equipped with a lifting tension sensor (61a) and a wireless tilt sensor (61b). The end effector (68) includes at least one of a hydraulic adaptive clamp, an electromagnetic chuck array, or a pallet-type lifting device.

9. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 1, characterized in that: The controller (18) is a PLC controller (18), which is electrically connected to the solenoid valves of the dual-axis tilt sensor (14), balance sensor, translation sensor (35), rotary encoder (13), lifting tension sensor (61a), wireless tilt sensor (61b), suspension tension sensor (65b), translation drive motor (37), slewing drive motor (16), hoisting device (7), luffing cylinder (9), and the drive elements of the end effector (68).

10. The intelligent hoisting structure for mechanical and electrical automation equipment according to claim 9, characterized in that: The PLC controller (18) is configured to perform the following control steps: Step 1: Read the chassis tilt angle data collected by the dual-axis tilt sensor (14), and control the hydraulic support leg (10) to extend and retract synchronously until the chassis tilt angle is ≤0.5°; Step 2: Receive the end effector selection command, control the spreader assembly (6) to move above the actuator storage rack, and complete the automatic docking and locking of the end effector (68); Step 3: Control the end effector (68) to clamp or adsorb the suspended equipment, control the hoisting equipment (7) to lift, and monitor the lifting weight through the lifting tension sensor (61a); Step 4: Control the equipment to lift it to 50mm off the ground and then stop it. Let the tilt slider (64) slide automatically along the tilt rail (63) to the center of gravity position. After the posture is stable, the suspension tension sensor (65b) confirms that the force on each lifting point is balanced. Step 5: Collect data from multiple sensors, and output compensation speed commands to the hoisting equipment (7) and rotary motor through Kalman filtering and fuzzy PID controller (18) to control the swing amplitude within ±3mm; Step 6: Receive the target translation or rotation command, and drive the corresponding motor to move until the target position is reached through real-time feedback from the translation sensor (35) or rotary encoder (13); Step 7: Control the hoisting equipment (7) to lower, measure the distance using a laser rangefinder to control deceleration and stop, and control the end effector (68) to release or disengage; Step 8: Reset the control spreader assembly (6), retract the hydraulic support leg (10), de-energize each actuator, and enter standby mode; The PLC controller (18) is also configured to perform at least one of the following safety protection mechanisms: overload protection, overturning warning, and power failure protection.

Images