Real-time monitoring method and equipment for cargo boom

Abstract

The invention provides a real-time monitoring method and device for a cargo boom, and the method comprises the following steps: S1, building a track model which comprises a rotation center shaft of a rotary table, a rotation center shaft of the cargo boom, a variable amplitude plane of the cargo boom, and a detection line in the extension direction of the cargo boom; s2, the track model is rotated along the rotation center shaft, the vertical distance between the real-time coordinates of the top end of the cargo boom and the variable amplitude plane is calculated as the monitoring distance, and the sidewise bending value is calculated through the monitoring distance; s3, the detection line is rotated along the rotation center shaft in the track model, the rotation angle of the detection line is a variable amplitude difference angle, and the deflection is calculated through the real-time coordinates of the top end of the cargo boom, the detection line and the sidewise bending value; and S4, the safety level of the cargo boom is judged according to the deflection and the sidewise bending value. The device has the beneficial effects that through the arrangement of the rotating center shaft and the rotary center shaft, the measuring device only needs to be installed at the top end of the rotary table and the top end of the cargo boom, the installation requirement is lowered, the monitoring precision is guaranteed, and meanwhile the installation cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of lifting equipment technology, and in particular relates to a method and equipment for real-time monitoring of lifting booms. Background Technology

[0002] As core heavy equipment in engineering construction, port logistics, energy development, and other fields, the safety, efficiency, and accuracy of crane lifting operations directly determine the quality of project progress and the safety of personnel and property. With the increasing complexity of industrial scenarios and the tightening of safety standards, information such as the boom length, boom angle, and spatial position of the boom head is crucial for the precise control of cranes. Traditional methods for obtaining the three-dimensional state of the boom head suffer from insufficient accuracy and poor real-time performance, or the operation mode that relies on manual observation and experience judgment is difficult to meet the current requirements for precise crane operation under complex working conditions.

[0003] The boom is the key load-bearing structure of a crane to achieve the core actions of "lifting, luffing, and slewing". Its condition directly determines the safety and accuracy of the operation. During the factory inspection and lifting operation of various lifting equipment, the condition of the boom needs to be detected through a series of manual testing methods to obtain the condition of the boom in two dimensions: when the boom is fully extended and not under load, and when it is under load. The results include lateral bending (lateral bending amount), deflection (vertical downward deflection), and amplitude (horizontal distance from the center axis of the boom rotation to the center of the hook). The real-time condition of the boom cannot be detected manually, and the testing process is complex and prone to errors. In existing technologies, the measurement process requires the use of a multi-dimensional monitoring system to acquire the multi-dimensional state values ​​(lateral bending, deflection, and amplitude) of each boom section in real time, and to distinguish between unloaded and loaded conditions for dynamic monitoring. For multi-section telescopic boom structures, lateral bending when unloaded is mainly caused by the adjustment error of the boom section gap, unilateral thermal expansion (such as sunlight exposure), or environmental wind force. Under the loaded condition, the additional load will exacerbate the boom deformation. At this time, it is necessary to monitor the coupling relationship between the load mass and the deformation parameters simultaneously, which requires high installation accuracy and the detection process is complex and costly.

[0004] In the patent CN118597995B entitled "Self-Iterative Detection Method for Lateral Bending of Crane Boom," when the crane boom is fully retracted and lifting the target object, the boom is controlled to perform a luffing motion, and the motion trajectory T of the RTK-GPS is recorded. By minimizing the sum of the squares of the distances from all points on trajectory T to the plane, the reference luffing plane C is calculated. The boom is then controlled to extend to the target length, and the position coordinates of the RTK-GPS at this time are obtained. The vertical distance from the RTK-GPS position to the reference plane C after the boom is extended is calculated, and this distance is the lateral bending P of the boom. However, the lateral bending value can only be measured at one rotation angle. In actual testing, it is necessary to simultaneously test the lateral bending value (the lateral error value of the boom relative to the normal state) under no-load and loaded conditions at different rotation angles. In this case, only one angle or load can be measured before retracting the boom, re-initializing, and then extending the boom again. This process takes 0.5-1 hour, which is quite time-consuming.

[0005] The patent with patent number CN115629411A, entitled "Measuring Method and Device for Measuring Boom Lateral Bending," describes a technical solution that involves acquiring the latitude and longitude information at points A, B, and C; calculating the lateral bending amount P of the boom based on the straight-line distances of AB, AC, and BC; comparing the actual lateral bending amount with a preset lateral bending threshold; and triggering an alarm when the actual lateral bending amount is greater than or equal to the preset threshold. The measuring device is installed at both ends of the basic boom, but the measuring device itself has errors. Combined with the installation errors of the equipment, the directly calculated parallel line error of the boom is relatively large, resulting in a high error in the calculation of the lateral bending amount.

[0006] The patent CN106744325A, entitled "A Method and Device for Measuring and Predicting Lateral Displacement of Crane Boom Head," calculates the lateral displacement direction and lateral offset value of the boom by measuring the straight-line distances from four measuring points along the axis of the boom bottom section support hinge at the boom head signal point during installation, before hoisting, or during hoisting. In actual installation, the measuring equipment needs to be debugged, and high installation accuracy is required to ensure that all measuring devices can receive the distance information normally. Furthermore, during the measurement process, obstructions or deviations from the measuring point may prevent measurement. Summary of the Invention

[0007] In view of this, the present invention aims to provide a method and device for real-time monitoring of crane booms, in order to solve at least one of the above-mentioned technical problems.

[0008] To achieve the above objectives, the technical solution of the present invention is implemented as follows: The first aspect of this invention provides a method for real-time monitoring of a crane boom, comprising the following steps: S1. Establish a trajectory model, which includes the rotation center axis of the turntable, the rotation center axis of the boom, the luffing plane of the boom, and the detection line along the extension direction of the boom. S2. The rotation trajectory model along the slewing center axis is used to calculate the real-time coordinates of the top of the crane boom and the vertical distance between the boom and the luffing plane as the monitoring distance. The lateral curvature value is then calculated based on the monitoring distance. S3. In the trajectory model, the detection line rotates along the rotation center axis. The rotation angle of the detection line is the amplitude difference angle. The deflection is calculated by the real-time coordinates of the top of the crane arm, the detection line, and the lateral bending value.

[0009] Furthermore, S1 includes the following steps: A first coordinate acquisition device is set on the turntable of the crane, a third acquisition device is set at the top of the boom, and a second coordinate acquisition device is set at a specified distance from the bottom of the boom. S11. Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector. S12, boom luffing, collect the coordinate trajectory of the third acquisition device, calculate the trajectory center, and obtain the rotation center axis of the boom based on the trajectory center and trajectory normal vector; S13. Luffing of the boom: draw a luffing plane parallel to the coordinate trajectory of the third acquisition device through the reference point, and collect the distance between the coordinates of the third acquisition device and the luffing plane as the foundation side bending distance. The reference point is the coordinate of the first data acquisition device during the luffing process of the S12 crane boom; S14. The crane boom extends, and the coordinate trajectory of the third acquisition device is used as the detection line.

[0010] Furthermore, S1 includes the following steps: A first coordinate acquisition device is installed on the turntable of the crane, and a third acquisition device is installed at the top of the crane boom. S11. Rotate the turntable, collect the coordinate trajectory of the first coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector; S12, boom luffing, collect the coordinate trajectory of the third acquisition device, calculate the trajectory center, and obtain the rotation center axis of the boom based on the trajectory center and trajectory normal vector; S13. Luffing of the boom: draw a luffing plane parallel to the coordinate trajectory of the third acquisition device through the reference point, and collect the distance between the coordinates of the third acquisition device and the luffing plane as the foundation side bending distance. The reference point is the coordinate of the first data acquisition device during the luffing process of the S12 crane boom; S14. The crane boom extends, and the coordinate trajectory of the third acquisition device is used as the detection line.

[0011] Furthermore, S2 includes the following steps: S21. Collect the real-time coordinates of the first coordinate acquisition device, and rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane; S22. Collect the real-time coordinates of the third coordinate acquisition device, and calculate the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane as the monitoring distance. S23. The side curvature value is the difference between the monitoring distance and the foundation side curvature distance.

[0012] Furthermore, S2 includes the following steps: S21. Collect the real-time coordinates of the first coordinate acquisition device, rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane, and move the amplitude plane along the normal of the amplitude plane so that the amplitude plane passes through the coordinate point of the third coordinate acquisition device at the initial moment of S1. S22. Collect the real-time coordinates of the third coordinate acquisition device, and calculate the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane as the monitoring distance. The monitoring distance is the lateral curvature value.

[0013] Furthermore, S3 includes the following steps: S31. Collect the intersection of the luffing plane and the boom rotation center axis, connect point A with the intersection to form the first vector, and connect the reference point with the intersection to form the second vector; S32. Calculate the amplitude difference angle by taking the inner product of the first and second vectors. S33. Rotate the detection line along the rotation center axis, and the rotation angle of the detection line is the amplitude difference angle; S34. Calculate the shortest distance from the real-time coordinates of the third coordinate acquisition device to the detection line after rotation as the first distance. The first distance and the lateral bending value are used to calculate the deflection value using the Pythagorean theorem.

[0014] Furthermore, S3 includes the following steps: S31. Collect the intersection of the luffing plane and the boom rotation center axis, connect point A with the intersection to form the first vector, and connect the reference point with the intersection to form the second vector; S32. Calculate the amplitude difference angle by taking the inner product of the first and second vectors. S33. Rotate the detection line along the rotation center axis, and the rotation angle of the detection line is the amplitude difference angle; S34. Draw a deflection plane through the rotated detection line. The deflection plane is perpendicular to the amplitude change plane. Calculate the vertical distance from the real-time coordinates of the third coordinate acquisition device to the deflection plane as the deflection value.

[0015] Furthermore, S3 also includes the following step: calculating the shortest distance between the real-time coordinates of the top of the crane boom and the rotation center axis as the real-time amplitude.

[0016] Furthermore, it also includes: S4. Determine the safety level of the crane boom based on the deflection and lateral bending values.

[0017] Furthermore, S4 includes the following steps: Determine the foundation safety level of the crane based on deflection and lateral bending. The safe range is when the deflection is not greater than the first deflection threshold and the lateral bending is not greater than the first lateral bending threshold. When the deflection exceeds the second deflection threshold, or the lateral bending exceeds the second lateral bending threshold, it is considered a dangerous range. When the deflection is greater than the first deflection threshold but not greater than the second deflection threshold, and the lateral bending is not greater than the second lateral bending threshold, it is within the controllable range. The range is controllable when the lateral bend is greater than the first lateral bend threshold but not greater than the second lateral bend threshold, and the deflection is not greater than the second deflection threshold.

[0018] Furthermore, S4 includes the following steps: Real-time torque is calculated using real-time amplitude and real-time load weight. The basic threshold corresponding to the real-time operating condition in the rated torque curve is calculated using an interpolation algorithm. The deformation influence coefficient is calculated based on the deflection value and the lateral bending value, and the correction threshold is calculated based on the deformation influence coefficient and the basic threshold. The dynamic threshold is calculated based on the correction threshold, slewing adjustment coefficient, wind speed adjustment coefficient, and torque limiter coefficient.

[0019] Furthermore, S4 includes the following steps: Determine the dynamic security level: If the real-time torque is less than 90% of the corrected threshold, and the basic safety level of the boom is within the safe range, and the slewing angle is within the non-restricted slewing range, it is determined to be in a safe state. If the real-time torque is less than 80% of the corrected threshold, and the basic safety level of the boom is within the safe range, and the slewing angle is within the slewing restriction range, it is determined to be in a safe state. If the real-time torque is not less than 95% of the correction threshold, it is determined to be in a restricted state; If the real-time torque is not less than 90% of the dynamic threshold, it is determined to be in a restricted state; The crane boom is in a dangerous area and is therefore classified as a restricted state. Otherwise, it is determined to be in a warning state; The real-time torque is not less than 90% of the correction threshold and is less than 95% of the correction threshold. The remaining safe torque is calculated using the correction threshold and the real-time torque, and then sent to the operator.

[0020] A second aspect of the present invention provides a real-time monitoring device for a crane boom, comprising: The coordinate acquisition module is configured to acquire the real-time coordinates of the top of the boom. The modeling module is configured to build a trajectory model, which includes the rotation center axis of the turntable, the rotation center axis of the boom, the luffing plane of the boom, and the detection line along the extension direction of the boom. The data processing module is configured to rotate along the rotation center axis trajectory model, calculate the real-time coordinates of the top of the boom and the vertical distance between the boom and the luffing plane as the monitoring distance, and calculate the lateral curvature value through the monitoring distance. In the trajectory model, the detection line rotates along the rotation center axis. The rotation angle of the detection line is the amplitude difference angle. The deflection is calculated by the real-time coordinates of the top of the crane arm, the detection line, and the lateral bending value.

[0021] Furthermore, the coordinate acquisition module includes a first coordinate acquisition device, a second coordinate acquisition device, and a third coordinate acquisition device. The first coordinate acquisition device is set on the turntable of the crane, the third acquisition device is set at the top of the boom, and the second coordinate acquisition device is set at a specified distance from the bottom of the boom. The steps for building a trajectory model in the modeling module are as follows: Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector; The boom luffing is adjusted, the coordinate trajectory of the third acquisition device is collected, the trajectory center is calculated, and the rotation center axis of the boom is obtained based on the trajectory center and the trajectory normal vector. The boom is luffing. A luffing plane is drawn through the reference point, parallel to the coordinate trajectory of the third acquisition device. The distance between the coordinates of the third acquisition device and the luffing plane is collected as the foundation side bending distance. The crane boom extends, and the coordinate trajectory of the third acquisition device is used as the detection line.

[0022] Furthermore, the data processing module calculates the lateral bending value using the following steps: Collect the real-time coordinates of the first coordinate acquisition device, and rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane; The real-time coordinates of the third coordinate acquisition device are collected, and the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane is calculated as the monitoring distance. The side curvature value is obtained by subtracting the foundation side curvature distance from the monitoring distance.

[0023] A third aspect of the present invention provides an electronic device including a processor and a memory communicatively connected to the processor and used to store processor-executable instructions, the processor being used to perform the method described in the first aspect above.

[0024] A fourth aspect of the present invention provides a server including at least one processor and a memory communicatively connected to the processor, the memory storing instructions executable by the at least one processor, the instructions being executed by the processor to cause the at least one processor to perform the method as described in the first aspect.

[0025] The fifth aspect of the present invention provides a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the method described in the first aspect.

[0026] Compared with the prior art, the real-time monitoring method and equipment for crane boom described in this invention have the following advantages: (1) The real-time monitoring method for crane boom described in this invention, by setting the rotation center axis and the slewing center axis, only requires the measuring device to be installed on the turntable and the top of the crane boom, which reduces the installation requirements, ensures the monitoring accuracy, and reduces the installation cost.

[0027] (2) The real-time monitoring method for crane boom described in this invention, S1 constructs a geometric reference model including the slewing center axis, the rotation center axis, the luffing plane and the detection line, providing a unified and stable coordinate reference system for subsequent real-time distance, deflection and lateral bending calculations, and mapping the original coordinates collected by the sensor to geometric quantities with clear engineering significance.

[0028] (3) The real-time monitoring method for crane boom described in this invention can effectively handle fluctuations and errors in the acquisition process through data denoising, three-point circle method and multiple sampling steps, improve trajectory fitting accuracy, and reduce the impact of equipment error, external environmental interference and other factors through multiple sampling and denoising process, thereby improving the reliability of monitoring results. Attached Figure Description

[0029] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the real-time monitoring method for the crane boom according to an embodiment of the present invention; Figure 2 This is a schematic diagram of step S1 as described in an embodiment of the present invention; Figure 3 This is a schematic diagram of step S2 as described in an embodiment of the present invention; Figure 4 This is a schematic diagram of step S3 in an embodiment of the present invention. Detailed Implementation

[0030] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0031] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0032] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0033] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0034] Example 1: like Figure 1 As shown, a method for real-time monitoring of a crane boom includes the following steps: S1. Establish a trajectory model, which includes the rotation center axis of the turntable, the rotation center axis of the boom, the luffing plane of the boom, and the detection line along the extension direction of the boom. S2. The rotation trajectory model along the slewing center axis is used to calculate the real-time coordinates of the top of the crane boom and the vertical distance between the boom and the luffing plane as the monitoring distance. The lateral curvature value is then calculated based on the monitoring distance. S3. In the trajectory model, the detection line rotates along the rotation center axis. The rotation angle of the detection line is the amplitude difference angle. The deflection is calculated by the real-time coordinates of the top of the crane arm, the detection line, and the lateral bending value. S4. Determine the safety level of the crane boom based on the deflection and lateral bending values.

[0035] S3 also includes the following steps: calculating the shortest distance between the real-time coordinates of the top of the crane boom and the slewing center axis as the real-time amplitude.

[0036] In some embodiments, S1 includes the following steps: A first coordinate acquisition device is installed on the turntable of the crane, a third acquisition device (third coordinate acquisition device) is installed at the top of the boom, and a second coordinate acquisition device is installed at a specified distance from the bottom of the boom; the third acquisition device mentioned below refers to the third coordinate acquisition device.

[0037] The first coordinate acquisition device, the second coordinate acquisition device, and the third coordinate acquisition device are located on the same side of the rotation center axis of the crane boom.

[0038] The first coordinate acquisition device, the second coordinate acquisition device, and the third coordinate acquisition device all use, but are not limited to, the existing Sinan Navigation N3 antenna.

[0039] The distance between the first coordinate acquisition device and the second coordinate acquisition device is 5 meters.

[0040] S11. Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector. The centers of the coordinate trajectory calculation circles of the first coordinate acquisition device and the second coordinate acquisition device are the center of the first trajectory circle and the center of the second trajectory circle, respectively; S11 specifically involves rotating the turntable, collecting the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculating the center of the first trajectory circle and the center of the second trajectory circle respectively, and obtaining the rotation center axis of the turntable based on the center of the first trajectory circle, the center of the second trajectory circle and the corresponding two trajectory normal vectors. Specifically, the crane boom is controlled to rotate significantly when fully retracted, and the coordinate trajectories of the first and second coordinate acquisition devices are collected to determine the center of the trajectory and the trajectory normal vector, thereby obtaining the rotation center axis.

[0041] The method for fitting the center of a circle using the coordinate trajectories of the first and second coordinate acquisition devices is as follows: The scheme for solving for the center and normal vector of the circle through the trajectory is as follows: 1. The center of the circle is determined using the three-point method; For three non-collinear points in a plane The center of its circumcircle is the intersection of the perpendicular bisectors of any two points (the center is equidistant from the three points, i.e., the radius). Let the center be... According to the definition of a circle, we can set up a system of equations: ; Subtract the first two equations and the last two equations to eliminate the difference. By combining the quadratic term with the quadratic term, we obtain two linear equations: ; Solving this system of linear equations will give us the center of the circle. .

[0042] 2. Solution Steps Because trajectory points fluctuate, directly calculating using any three points will result in errors. Accuracy needs to be improved through "multiple sampling + noise reduction + dual-circle comparison," as follows: (1) Data processing First, outliers are removed, and the centroid (approximate plane center) of the trajectory points is calculated: ; Calculate the distance from each point to the centroid: ; Maintain distance Points within the range The average distance, (where the standard deviation is used to remove outliers), resulting in a denoised point set. After denoising, if the trajectory points are arranged in time / motion order (such as robot motion trajectory), the average 3D coordinates of each point and its k preceding and following points are taken as the smoothing point to reduce local fluctuations. (k can be 1 to 3, but 1 is used in this scheme to avoid excessive smoothing that could cause the center of the circle to shift).

[0043] (2) Find the center of a circle by using multiple sets of three points within a single circle (to reduce random errors, remove the Z-axis from the points); For each denoised circle (let's call them circle 1 and circle 2), multiple sets of non-collinear three-point intervals are randomly selected. The center of each set is calculated using the "three-point circle determination method," and the average coordinates of all the center points are taken as the "candidate center" of that circle. Forty different sets of three-point intervals (each set of three points is unique and non-collinear) are selected through random sampling to obtain 40 temporary center points. Then the candidate center of circle 1 .

[0044] (3) Solving for the center of the circle; Without considering the z-axis center, the average of the two center values ​​is taken as the final center: (The circular trajectory points collected by the first coordinate acquisition device fluctuate less, so the candidate center of the circle is given a higher weight of 0.7, and the weighted average is calculated.)

[0045] (4) Solve for the axis of rotation; Construct the covariance matrix (key matrix), and the centered points satisfy... Define the covariance matrix M (a 3×3 matrix), and calculate its elements as follows: ; Solve the characteristic equation Three eigenvalues ​​were obtained. (the smallest eigenvalue); Will Substitution Solve the system of linear equations to obtain the corresponding eigenvectors. ; Given normal vector and the center The coordinates of any point (P(x,y,z)) on the rotation axis satisfy: ; illustrate: When t=0, (P=P_0) (the line passes through the known point); The positive and negative values ​​of (t) are extended along the normal vector or its opposite direction (since the direction of the normal vector can be positive or negative, it does not affect the parallel relationship).

[0046] 3. Plane solution; (Among them, the center of gravity:) ); S12, boom luffing, collect the coordinate trajectory of the third acquisition device, calculate the trajectory center, and obtain the rotation center axis of the boom based on the trajectory center and trajectory normal vector; The center of the coordinate trajectory calculated by the third acquisition device is the center of the third trajectory circle.

[0047] S12 specifically refers to: boom luffing, collecting the coordinate trajectory of the third coordinate acquisition device, calculating the center of the third trajectory circle, and obtaining the rotation center axis of the boom based on the center of the third trajectory circle and the corresponding trajectory normal vector; Specifically, when the crane boom is fully retracted, it undergoes significant vertical luffing. The coordinate trajectory of the boom is captured by a third acquisition device, and the fitted plane is used as the reference luffing plane. The normal vector of the reference luffing plane is then calculated. The center of the circle is obtained by fitting the equation of the circle based on the coordinate trajectory of the third acquisition device. The normal vector of the reference luffing plane is then translated to the position of the center of the circle to obtain the rotation center axis of the boom.

[0048] The method for determining the center is the same as in S11; The optimization method of median filtering is used to extract the fitting plane, which effectively reduces the impact of the positioning error fluctuation of the measuring device and improves the calculation accuracy of the lateral bending, deflection and amplitude. In contrast, the existing technology tends to install measuring devices at both ends of the foundation boom. The rotation center axis of this application is obtained by fitting calculation. Compared with the traditional method of installing measuring devices at both ends of the boom, the measurement process of the existing technology does not require the calculation of the rotation center, and the data of its measuring device itself is not fitted. Therefore, it has its own error, and the directly calculated boom parallel line error is large, resulting in a high error in the calculation of lateral bending.

[0049] S13. Draw a variable amplitude plane parallel to the coordinate trajectory of the third acquisition device (the fitting plane of the coordinate trajectory of the third acquisition device acquired in S12) through the reference point. Collect the distance between the coordinates of the third acquisition device and the variable amplitude plane during the variable amplitude process as the foundation side bending distance. It can be the distance between a coordinate point in the coordinate trajectory of the third acquisition device acquired in S12 and the variable amplitude plane, or it can be the average of the distances between all coordinate points in the coordinate trajectory of the third acquisition device acquired in S12 and the variable amplitude plane.

[0050] The reference point is the coordinate of the first coordinate acquisition device during the Luffing process of the S12 crane boom (it can be the coordinate at a certain moment during the Luffing process of the crane boom, or it can be calculated by averaging all the coordinates during the Luffing process of the crane boom).

[0051] S14. The crane arm extends, and the coordinate trajectory of the third acquisition device (the coordinate trajectory of the first 5 meters) is used as the detection line.

[0052] The detection line near the top or front of the arm is highly sensitive to deflection and lateral bending: Being closer to the end / elongated section better reflects beam end deformation, facilitating early detection of increased deflection. Using a short segment (5m) reduces the cumulative error of the long arm: Long-distance fitting is easily affected by local uneven deformation; short-segment fitting offers more stable local geometry and requires less computation. The detection line serves as a unified reference for rotation to determine deflection: Subsequent rotation of the line around the axis of rotation yields the theoretical position, providing a more intuitive comparison with real-time coordinates.

[0053] S1 constructs a geometric reference model that includes a slewing center axis, a rotation center axis, a luffing plane, and a detection line. This provides a unified and stable coordinate reference system for subsequent real-time distance / deflection / lateral bending calculations. It maps the original coordinates collected by the sensors to geometric quantities (axis, plane, line) with clear engineering significance. It can decompose complex three-dimensional motion into several simple transformations such as axial rotation, planar luffing, and extension along the boom direction, which facilitates decoupling calculations and fault diagnosis. It also facilitates docking with the crane's body parameters (slewing center, amplitude curve, torque diagram).

[0054] In other embodiments, S1 includes the following steps: The first coordinate acquisition device is installed only on the turntable of the crane, and the third acquisition device is installed at the top of the crane boom; The first coordinate acquisition device and the third coordinate acquisition device are located on the same side of the rotation center axis of the crane boom; S11. Rotate the turntable, collect the center of the trajectory circle calculated by the first coordinate acquisition device, and obtain the rotation center axis of the turntable based on the center of the trajectory circle and the trajectory normal vector; The center of the trajectory circle calculated by the first coordinate acquisition device is the center of the first trajectory circle.

[0055] S11 specifically involves rotating the turntable, collecting the coordinate trajectory of the first coordinate acquisition device, calculating the center of the first trajectory circle, and obtaining the rotation center axis of the turntable based on the center of the first trajectory circle and the corresponding trajectory normal vector.

[0056] S12, boom luffing, collect the coordinate trajectory of the third acquisition device, calculate the trajectory center, and obtain the rotation center axis of the boom based on the trajectory center and trajectory normal vector; The center of the coordinate trajectory calculated by the third acquisition device is the center of the third trajectory circle.

[0057] S12 specifically refers to: boom luffing, collecting the coordinate trajectory of the third coordinate acquisition device, calculating the center of the third trajectory circle, and obtaining the rotation center axis of the boom based on the center of the third trajectory circle and the corresponding trajectory normal vector; S13. Luffing of the boom: draw a luffing plane parallel to the coordinate trajectory of the third acquisition device through the reference point, and collect the distance between the coordinates of the third acquisition device and the luffing plane as the foundation side bending distance. Specifically, S13 is: boom luffing, draw a luffing plane parallel to the coordinate trajectory of the third coordinate acquisition device through the reference point, and collect the distance between the coordinates of the third coordinate acquisition device and the luffing plane during the luffing process as the foundation side bending distance. S14. The crane boom extends, and the coordinate trajectory of the third acquisition device is used as the detection line. By rotating the turntable to collect coordinate data from the first and third coordinate acquisition devices, the rotation center axis can be determined; by adjusting the boom luffing to collect coordinate data from the first and third coordinate acquisition devices, the rotation center axis can be determined; the luffing plane and detection line are the same as above and will not be repeated here. Setting up only two coordinate acquisition devices (i.e., eliminating the second coordinate acquisition device) reduces costs and simplifies implementation, yet still provides basic information on the rotation and revolution axes, making it suitable for economical deployments.

[0058] In other embodiments, S1 includes the following steps: Three-dimensional scanning is performed during the rotation of the turntable, and the rotation center axis is collected through scanning data. Three-dimensional scanning is also performed during the luffing process of the crane boom, and the rotation center axis and luffing plane are collected through scanning data. The detection line is formed by fitting the crane boom.

[0059] The specific method is as follows: The laser beam of a laser scanner measures the distance from the object's surface to the sensor, generating high-density point cloud data. The scanning is performed while the crane is in operation, either by rotating the scanning mode or by scanning simultaneously through multiple sensors, during the crane's slewing table or boom luffing. Each scan generates a large amount of point cloud data, containing the spatial location (X, Y, Z coordinates) of each measurement point. Data cleaning and noise removal are performed, including removing outliers, filling in missing data, and smoothing. Using the point cloud data, 3D reconstruction algorithms are then used to convert the point cloud into a mesh model or other forms of geometric model.

[0060] The geometric model obtained during the turntable rotation process can capture the rotation center axis; The geometric model obtained during the boom luffing process can capture the rotation center axis and the luffing plane; The geometric model of the crane boom extension process can be used to collect detection lines.

[0061] In some embodiments, S2 includes the following steps: S21. Collect the real-time coordinates of the first coordinate acquisition device, and rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane; The steps for calculating the rotation angle of the model rotating along the rotation center axis are as follows: the rotation center axis of the model coincides with the actual rotation center axis, the model is moved along the axial direction of the rotation center axis, and the model is rotated along the rotation center axis until the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane, and the rotation angle is recorded. Based on the rotation angle, the coordinates of the model's reference point, amplitude plane, rotation center axis, and detection line are recalculated.

[0062] The current rotation angle of the crane turntable can also be used as the rotation angle (turning angle) of the model.

[0063] S22. Collect the real-time coordinates of the third coordinate acquisition device, and calculate the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane as the monitoring distance. S23. The side curvature value is the difference between the monitoring distance and the foundation side curvature distance.

[0064] The trajectory model is rotated to the current angle along the rotation center axis. The vertical distance (monitoring distance) from the top real-time coordinates to the amplitude-changing plane is calculated, and then the foundation lateral curvature is subtracted to obtain the actual lateral curvature value. The three-dimensional real-time coordinates are transformed to a reference system consistent with the static geometric model, thereby eliminating the coordinate changes caused by equipment movement and accurately obtaining the true lateral curvature value of the structure, reducing misjudgments caused by turntable angle and installation deviations. In some embodiments, S2 includes the following steps: S21. Collect the real-time coordinates of the first coordinate acquisition device, rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane, and move the amplitude plane along the normal of the amplitude plane so that the amplitude plane passes through the coordinate point of the third coordinate acquisition device at the initial moment of S1. S22. Collect the real-time coordinates of the third coordinate acquisition device, and calculate the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane as the monitoring distance. The monitoring distance is the lateral curvature value.

[0065] The variable amplitude plane passes through the coordinate point of the third coordinate acquisition device at the initial moment of S1, which reduces the amount of calculation, and the monitoring distance is the side curvature value.

[0066] In other embodiments, S2 includes the following steps: In the trajectory model of S1, a reference point is set. In S2, the real-time position of the reference point is collected. The trajectory model is moved so that the reference point set in the trajectory model coincides with the real-time position of the reference point. Then, the real-time coordinates of the top of the boom are collected. The vertical distance between the real-time coordinates of the top of the boom and the luffing plane is calculated as the monitoring distance. The monitoring distance minus the foundation lateral bending distance is the lateral bending value.

[0067] In some embodiments, S3 includes the following steps: S31. Collect the intersection of the luffing plane and the boom rotation center axis, connect point A with the intersection to form the first vector, and connect the reference point with the intersection to form the second vector; Specifically, the boom in step S31 is the boom of the crane arm.

[0068] Point A is the real-time coordinate point acquired by the second coordinate acquisition device.

[0069] S31 specifically involves: acquiring the intersection of the luffing plane and the rotation center axis of the boom; connecting the real-time coordinate points acquired by the second coordinate acquisition device with the intersection to form a first vector; and connecting the reference point with the intersection to form a second vector. S32. Calculate the amplitude difference angle by taking the inner product of the first and second vectors; S33. Rotate the detection line along the rotation center axis, and the rotation angle of the detection line is the amplitude difference angle; S34 can be the following steps: S34. Calculate the shortest distance (the perpendicular length from the real-time coordinates to the rotated detection line) from the real-time coordinates of the third coordinate acquisition device as the first distance. The first distance and the lateral bending value are used to calculate the deflection value using the Pythagorean theorem.

[0070] The formula is as follows: First distance 2 - Lateral bending value 2 =Deflection value 2 ; The deflection is synthesized by decomposing the lateral bending value at right angles: decoupling "in-plane lateral bending" from "vertical / lateral displacement" is beneficial for diagnosing different deformation forms such as bending and torsion.

[0071] S34 can also be the following steps: S34. Draw a deflection plane through the rotated detection line. The deflection plane is perpendicular to the amplitude change plane. Calculate the vertical distance from the real-time coordinates of the third coordinate acquisition device to the deflection plane as the deflection value. Defining the deflection as the distance to a deflection plane perpendicular to the amplitude change plane facilitates filtering and threshold judgment, and reduces the amount of calculation.

[0072] In some embodiments, S3 includes the following steps: The amplitude difference angle is obtained by detecting the boom elevation angle of the crane itself. S34. Calculate the shortest distance (the perpendicular length from the real-time coordinates to the rotated detection line) from the real-time coordinates of the third coordinate acquisition device as the first distance. The first distance and the lateral bending value are used to calculate the deflection value using the Pythagorean theorem. The formula is as follows: First distance 2 - Lateral bending value 2 =Deflection value 2 ; S3 also includes the following steps: calculating the shortest distance between the real-time coordinates of the top of the crane boom and the slewing center axis as the real-time amplitude.

[0073] S4 includes the following steps: S41. Determine the foundation safety level of the crane based on deflection and lateral bending. The deformation influence coefficient is used to quantify the reduction in load-bearing capacity caused by the deformation of the boom structure.

[0074] When the deflection is not greater than the first deflection threshold and the lateral bending is not greater than the first lateral bending threshold, it is within the safe range, with a coefficient of 1.0 (the structure is within the safe deformation range). When the deflection exceeds the second deflection threshold or the lateral bending exceeds the second lateral bending threshold, it is considered a dangerous range, and the coefficient drops directly to 0.7 (the structural deformation has significantly affected safety). When the deflection is greater than the first deflection threshold but not greater than the second deflection threshold, and the lateral bending is not greater than the second lateral bending threshold, it is within the controllable range, and the coefficient decreases linearly to 0.85 (the structural deformation has slightly affected the safety). When the lateral bending is greater than the first lateral bending threshold but not greater than the second lateral bending threshold, and the deflection is not greater than the second deflection threshold, it is within the controllable range, and the coefficient decreases linearly to 0.85 (the structural deformation has slightly affected the safety).

[0075] The first deflection threshold, the second deflection threshold, the first lateral bending threshold, and the second lateral bending threshold are all obtained by multiplying the boom length by a coefficient, which is obtained from the parameter table provided by the crane manufacturer.

[0076] The coefficients are set based on the yield strength test data of the boom material, and each coefficient level corresponds to a 15%-20% reduction in the structural safety margin.

[0077] S42. The real-time torque is calculated using the real-time amplitude and the real-time load weight. Real-time torque is a fundamental indicator for measuring the load risk of a crane. The calculation formula is: Real-time torque M = Load weight (Q) × Corrected amplitude (L). Where: Load weight (Q) is obtained from the crane's weighing module; Traditional amplitude is estimated only by elevation angle and boom length (L=boom length×cosθ). By directly measuring the horizontal distance from the boom head to the center of rotation and combining it with deflection data for correction: when the deflection is S, the actual amplitude L = L0 + S × sinθ (θ is the boom elevation angle), the amplitude measurement deviation caused by boom bending is solved. L0 is the horizontal distance from the coordinates of the third sensor to the center of rotation.

[0078] Different crane operating conditions will have different lifting capacity tables. Real-time lifting weight is collected, and the working restricted area boundary is generated based on the lifting capacity table. Polar coordinates are established with the rotation center as the origin. The real-time rotation angle (α) obtained by the information acquisition module is combined with the current amplitude (L) to form a polar coordinate point (α,L). The geometric collision detection algorithm is used to determine whether the point falls into the restricted area. Taking a certain crane as an example, if α is between -30° and +30° and L > 5m, it is determined to be a high-risk area; if α is between +30° and +60° or between -30° and -60° and L > 8m, it is determined to be a warning area.

[0079] S43. Use an interpolation algorithm to calculate the basic threshold corresponding to the real-time operating condition in the rated torque curve; The basic threshold is derived from the rated torque curve preset at the factory. This curve is a three-dimensional surface drawn through finite element analysis and physical tests: the horizontal axis is the boom length (5m-50m), the vertical axis is the elevation angle (30°-80°), and the Z-axis is the maximum allowable torque for the corresponding working condition. The system accurately calls the basic threshold for the corresponding working condition (error ≤1%) based on the current boom extension length and elevation angle data through an interpolation algorithm. Special working conditions (such as when the outrigger is half-extended) will trigger curve switching, and the basic threshold will be automatically reduced by 20%-30% (due to the reduced outrigger span leading to decreased stability).

[0080] S44. Calculate the deformation influence coefficient based on the deflection value and the lateral bending value, and calculate the correction threshold based on the deformation influence coefficient and the basic threshold. The correction threshold = base threshold × deformation influence coefficient, which is the actual safety upper limit after considering structural deformation. For example: When a 25t truck crane has a boom length of 30m and an elevation angle of 45°, the foundation threshold is 120kN. m; If the current deflection is 4‰L (L=21.2m with a 30m arm length, deflection=84.8mm), and the deformation influence coefficient is 0.925, then the corrected threshold is 120×0.925=111kN. m; the deformation influence coefficient is calculated based on the mapping table provided by the manufacturer and the real-time deflection.

[0081] This calculation ensures that the safety limit is lowered in advance when the structure has already deformed, leaving more safety margin.

[0082] By calculating real-time torque and corrected amplitude data, the load situation of the crane in actual operation can be measured more accurately. Compared with traditional technology that directly measures the distance from the top of the boom to the center of rotation and combines it with deflection correction, the amplitude measurement error caused by boom bending is significantly reduced. Such torque analysis can effectively assess the load risk of the crane and reduce the possibility of structural damage. S45. Calculate the dynamic threshold based on the correction threshold, slewing adjustment coefficient, wind speed adjustment coefficient, and torque limiter coefficient.

[0083] The dynamic threshold is the final execution threshold that takes into account environmental factors. The core adjustment logic includes: when the slewing angle enters the warning zone, the threshold is reduced by 10%; when entering the high-risk zone, the threshold is reduced by 20% (to avoid collision between the boom and obstacles); when the wind speed is >10m / s, the threshold is reduced by an additional 15% (wind load increases the force on the boom); when the torque coefficient (torque limiter coefficient) exceeds the alarm coefficient K1, the threshold is reduced by an additional 15%; the dynamic threshold = the corrected threshold × (1 - slewing adjustment coefficient - wind speed adjustment coefficient - torque limiter coefficient), and the adjustment coefficients are accumulated when multiple factors are superimposed (the maximum reduction does not exceed 40%). By monitoring structural deformation data such as deflection and lateral bending values ​​in real time, and combining dynamic thresholds and deformation influence coefficients, this technology can promptly determine the safety status of the crane boom. Especially when facing changes in the external environment (such as increased wind speed or changes in the crane's working angle), the system can dynamically adjust the safety threshold according to these changes, effectively preventing overload and accidents.

[0084] Slewing adjustment factor: The "maximum control current" corresponding to the maximum permissible slewing speed under the current operating conditions is scaled proportionally to a safe range. A common calculation is Imax_adjust = Imin + (Imax_adjust) / Imin. Imin)×rate, where rate is retrieved from the mapping table (provided by the manufacturer).

[0085] Wind speed adjustment coefficient: Calculation basis Pwind=∑C Kh q F, where q≈v² / 16 (wind pressure is related to the square of wind speed), Kh is the height correction, C is the flow resistance coefficient, and F is the windward area; the wind load is equivalent to the increment of the overturning moment, and thus the coefficient to be reduced is obtained.

[0086] Torque limiter coefficient: Calculated based on K=K2-Mt / Mn, where Mt is the limiter trigger threshold torque, and Mn is the crane's rated torque. Combining standards and operating conditions, this is refined into an application formula for alarm / cutoff coefficients: Cutoff coefficient (K2) = M2 / Mn = (1 + extreme dynamic load redundancy rate), Alarm coefficient (K1) = M1 / Mn = (1 - dynamic load redundancy rate). Where M2 is the cutoff torque, ranging from 110% to 130% of the crane's rated torque, and M1 is the alarm torque, ranging from 85% to 95% of the crane's rated torque.

[0087] S46. Dynamic security level determination: If the real-time torque is less than 90% of the corrected threshold (corrected threshold), and the basic safety level of the boom is within the safe range, and the slewing angle is within the non-slewing restricted area, it is determined to be in a safe state. The following revised thresholds are all corrected thresholds.

[0088] If the real-time torque is less than 80% of the corrected threshold, and the basic safety level of the boom is within the safe range, and the slewing angle is within the slewing restriction range, it is determined to be in a safe state. The restricted area for slewing is provided by the crane manufacturer.

[0089] If the real-time torque is not less than 95% of the correction threshold, it is determined to be in a restricted state; If the real-time torque is not less than 90% of the dynamic threshold, it is determined to be in a restricted state; The crane boom is in a dangerous area and is therefore classified as a restricted state. Otherwise, it is determined to be in a warning state; The real-time torque is not less than 90% of the correction threshold and is less than 95% of the correction threshold. The remaining safe torque is calculated using the correction threshold and the real-time torque, and then sent to the operator.

[0090] The conditions for triggering the warning status include two types of scenarios: Torque type: Real-time torque ≥ 90% but < 95% of the corrected threshold, calculate the remaining safe torque, remaining safe torque = corrected threshold - real-time torque, and display it, prompting the operator that they are about to approach the safe limit; Deformation / position type: Deflection is between the first deflection threshold and the second deflection threshold, or lateral bending is between the first lateral bending threshold and the second lateral bending threshold, or the turning angle enters the warning zone and the real-time torque is not below the dynamic threshold), at this time, abnormal parameters (such as excessive lateral bending) are highlighted.

[0091] A real-time monitoring device for crane boom, comprising: The coordinate acquisition module is configured to acquire the real-time coordinates of the top of the boom. The modeling module is configured to build a trajectory model, which includes the rotation center axis of the turntable, the rotation center axis of the boom, the luffing plane of the boom, and the detection line along the extension direction of the boom. The data processing module is configured to rotate along the rotation center axis trajectory model, calculate the real-time coordinates of the top of the boom and the vertical distance between the boom and the luffing plane as the monitoring distance, and calculate the lateral curvature value through the monitoring distance. In the trajectory model, the detection line rotates along the rotation center axis. The rotation angle of the detection line is the amplitude difference angle. The deflection is calculated by the real-time coordinates of the top of the crane arm, the detection line, and the lateral bending value.

[0092] The coordinate acquisition module includes a first coordinate acquisition device, a second coordinate acquisition device and a third coordinate acquisition device. The first coordinate acquisition device is set on the turntable of the crane, the third acquisition device is set at the top of the boom, and the second coordinate acquisition device is set at a specified distance from the bottom of the boom. The steps for building a trajectory model in the modeling module are as follows: Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector; The boom luffing is adjusted, the coordinate trajectory of the third acquisition device is collected, the trajectory center is calculated, and the rotation center axis of the boom is obtained based on the trajectory center and the trajectory normal vector. The boom is luffing. A luffing plane is drawn through the reference point, parallel to the coordinate trajectory of the third acquisition device. The distance between the coordinates of the third acquisition device and the luffing plane is collected as the foundation side bending distance. The crane boom extends, and the coordinate trajectory of the third acquisition device is used as the detection line.

[0093] The centers of the coordinate trajectory calculation circles of the first coordinate acquisition device and the second coordinate acquisition device are the center of the first trajectory circle and the center of the second trajectory circle, respectively; The coordinate trajectory calculation center of the third coordinate acquisition device is the center of the third trajectory circle; The third acquisition device is the third coordinate acquisition device.

[0094] The specific steps for the modeling module to build a trajectory model are as follows: Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the first trajectory circle and the center of the second trajectory circle respectively, and obtain the rotation center axis of the turntable based on the center of the first trajectory circle, the center of the second trajectory circle and the corresponding two trajectory normal vectors; The boom luffing is adjusted, the coordinate trajectory of the third coordinate acquisition device is collected, the center of the third trajectory circle is calculated, and the rotation center axis of the boom is obtained based on the center of the third trajectory circle and the trajectory normal vector. The boom is luffing. A luffing plane is drawn through the reference point, parallel to the coordinate trajectory of the third coordinate acquisition device. The distance between the coordinates of the third coordinate acquisition device and the luffing plane during the luffing process is collected as the foundation side bending distance. The crane boom extends, and the coordinate trajectory of the third coordinate acquisition device is used as the detection line.

[0095] The steps for the data processing module to calculate the lateral bending value are as follows: Collect the real-time coordinates of the first coordinate acquisition device, and rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane; The real-time coordinates of the third coordinate acquisition device are collected, and the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane is calculated as the monitoring distance. The side curvature value is obtained by subtracting the foundation side curvature distance from the monitoring distance.

[0096] Beneficial effects: 1. By setting up a rotating center axis and a slewing center axis, the measuring device only needs to be installed on the turntable and the top of the crane boom, reducing installation requirements and ensuring monitoring accuracy while lowering installation costs. This simplifies operation for the operator. Some technical requirements dictate that the measuring device be installed parallel to the foundation boom, which, from a practical standpoint, places excessive demands on the equipment's installation accuracy. 2. This method uses median filtering to extract the fitting plane, which effectively reduces the impact of fluctuations in the positioning error of the measuring device and improves the calculation accuracy of the lateral bending, deflection and amplitude. Existing technologies tend to install measuring devices at both ends of the foundation boom, but the measuring devices themselves have errors, and the directly calculated boom parallel line error is large, resulting in a high calculation error of the lateral bending amount.

[0097] 3. This method only requires initialization to build the trajectory model before testing. Other processes depend on the operator's habits and testing procedures. Some technical requirements necessitate re-initialization under different loads, which increases the overall testing time.

[0098] 4. This method allows for quick installation via external connection and does not require wiring to the crane, making it applicable to all crane models.

[0099] Example 2: An electronic device includes a processor and a memory communicatively connected to the processor and used to store processor-executable instructions, the processor being used to execute the method described in Embodiment 1 above.

[0100] Example 3: A server includes at least one processor and a memory communicatively connected to the processor, the memory storing instructions executable by the at least one processor to cause the at least one processor to perform the method as described in Embodiment 1.

[0101] Example 4: A computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in Embodiment 1.

[0102] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

[0103] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. 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.

Claims

1. A method for real-time monitoring of a crane boom, characterized in that, Includes the following steps: S1. Establish a trajectory model, which includes the rotation center axis of the turntable, the rotation center axis of the boom, the luffing plane of the boom, and the detection line along the extension direction of the boom. S2. The rotation trajectory model along the slewing center axis is used to calculate the real-time coordinates of the top of the crane boom and the vertical distance between the boom and the luffing plane as the monitoring distance. The lateral curvature value is then calculated based on the monitoring distance. S3. In the trajectory model, the detection line rotates along the rotation center axis. The rotation angle of the detection line is the amplitude difference angle. The deflection is calculated by the real-time coordinates of the top of the crane arm, the detection line, and the lateral bending value.

2. The method for real-time monitoring of a crane boom according to claim 1, characterized in that, S1 includes the following steps: A first coordinate acquisition device is set on the turntable of the crane, a third coordinate acquisition device is set at the top of the boom, and a second coordinate acquisition device is set at a specified distance from the bottom of the boom. S11. Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector. S12, boom luffing, collect coordinate trajectory data from the third coordinate acquisition device, calculate the trajectory center, and obtain the boom rotation center axis based on the trajectory center and trajectory normal vector; S13. Luffing of the boom: draw a luffing plane parallel to the coordinate trajectory of the third coordinate acquisition device through the reference point, and collect the distance between the coordinates of the third coordinate acquisition device and the luffing plane as the foundation side bending distance. The reference point is the coordinate of the first data acquisition device during the luffing process of the S12 crane boom; S14. The crane boom extends, and the coordinate trajectory of the third coordinate acquisition device is used as the detection line.

3. The method for real-time monitoring of a crane boom according to claim 1, characterized in that, S1 includes the following steps: A first coordinate acquisition device is installed on the turntable of the crane, and a third coordinate acquisition device is installed at the top of the crane boom. S11. Rotate the turntable, collect the coordinate trajectory of the first coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector; S12, boom luffing, collect coordinate trajectory data from the third coordinate acquisition device, calculate the trajectory center, and obtain the boom rotation center axis based on the trajectory center and trajectory normal vector; S13. Luffing of the boom: draw a luffing plane parallel to the coordinate trajectory of the third coordinate acquisition device through the reference point, and collect the distance between the coordinates of the third coordinate acquisition device and the luffing plane as the foundation side bending distance. The reference point is the coordinate of the first data acquisition device during the luffing process of the S12 crane boom; S14. The crane boom extends, and the coordinate trajectory of the third coordinate acquisition device is used as the detection line.

4. The method for real-time monitoring of a crane boom according to claim 1, characterized in that: S2 includes the following steps: S21. Collect the real-time coordinates of the first coordinate acquisition device, and rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane; S22. Collect the real-time coordinates of the third coordinate acquisition device, and calculate the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane as the monitoring distance. S23. The side curvature value is the difference between the monitoring distance and the foundation side curvature distance.

5. The method for real-time monitoring of a crane boom according to claim 2, characterized in that: S2 includes the following steps: S21. Collect the real-time coordinates of the first coordinate acquisition device, rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane, and move the amplitude plane along the normal of the amplitude plane so that the amplitude plane passes through the coordinate point of the third coordinate acquisition device at the initial moment of S1. S22. Collect the real-time coordinates of the third coordinate acquisition device, and calculate the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane as the monitoring distance. The monitoring distance is the lateral curvature value.

6. The method for real-time monitoring of a crane boom according to claim 4, characterized in that: S3 includes the following steps: S31. Collect the intersection of the luffing plane and the boom rotation center axis, connect point A with the intersection to form the first vector, and connect the reference point with the intersection to form the second vector; S32. Calculate the amplitude difference angle by taking the inner product of the first and second vectors. S33. Rotate the detection line along the rotation center axis, and the rotation angle of the detection line is the amplitude difference angle; S34. Calculate the shortest distance from the real-time coordinates of the third coordinate acquisition device to the detection line after rotation as the first distance. The first distance and the lateral bending value are used to calculate the deflection value using the Pythagorean theorem.

7. The method for real-time monitoring of a crane boom according to claim 4, characterized in that: S3 includes the following steps: S31. Collect the intersection of the luffing plane and the boom rotation center axis, connect point A with the intersection to form the first vector, and connect the reference point with the intersection to form the second vector; S32. Calculate the amplitude difference angle by taking the inner product of the first and second vectors. S33. Rotate the detection line along the rotation center axis, and the rotation angle of the detection line is the amplitude difference angle; S34. Draw a deflection plane through the rotated detection line. The deflection plane is perpendicular to the amplitude change plane. Calculate the vertical distance from the real-time coordinates of the third coordinate acquisition device to the deflection plane as the deflection value.

8. The method for real-time monitoring of a crane boom according to claim 1, characterized in that, S3 also includes the following step: calculating the shortest distance between the real-time coordinates of the top of the crane boom and the rotation center axis as the real-time amplitude.

9. A method for real-time monitoring of a crane boom according to claim 8, characterized in that, Also includes: S4. Determine the safety level of the crane boom based on the deflection and lateral bending values.

10. A method for real-time monitoring of a crane boom according to claim 9, characterized in that: S4 includes the following steps: Determine the foundation safety level of the crane based on deflection and lateral bending. The safe range is when the deflection is not greater than the first deflection threshold and the lateral bending is not greater than the first lateral bending threshold. When the deflection exceeds the second deflection threshold, or the lateral bending exceeds the second lateral bending threshold, it is considered a dangerous range. When the deflection is greater than the first deflection threshold but not greater than the second deflection threshold, and the lateral bending is not greater than the second lateral bending threshold, it is within the controllable range. The range is controllable when the lateral bend is greater than the first lateral bend threshold but not greater than the second lateral bend threshold, and the deflection is not greater than the second deflection threshold.

11. A method for real-time monitoring of a crane boom according to claim 10, characterized in that: S4 includes the following steps: Real-time torque is calculated using real-time amplitude and real-time load weight. The basic threshold corresponding to the real-time operating condition in the rated torque curve is calculated using an interpolation algorithm. The deformation influence coefficient is calculated based on the deflection value and the lateral bending value, and the correction threshold is calculated based on the deformation influence coefficient and the basic threshold. The dynamic threshold is calculated based on the correction threshold, slewing adjustment coefficient, wind speed adjustment coefficient, and torque limiter coefficient. Determine the dynamic security level: If the real-time torque is less than 90% of the corrected threshold, and the basic safety level of the boom is within the safe range, and the slewing angle is within the non-restricted slewing range, it is determined to be in a safe state. If the real-time torque is less than 80% of the corrected threshold, and the basic safety level of the boom is within the safe range, and the slewing angle is within the slewing restriction range, it is determined to be in a safe state.

12. The method for real-time monitoring of a crane boom according to claim 11, characterized in that, S4 includes the following steps: Determining dynamic security levels also includes: If the real-time torque is not less than 95% of the correction threshold, it is determined to be in a restricted state; If the real-time torque is not less than 90% of the dynamic threshold, it is determined to be in a restricted state; The crane boom is in a dangerous area and is therefore classified as a restricted state. Otherwise, it is determined to be in a warning state; The real-time torque is not less than 90% of the correction threshold and is less than 95% of the correction threshold. The remaining safe torque is calculated using the correction threshold and the real-time torque, and then sent to the operator.

13. A real-time monitoring device for a crane boom, characterized in that, include: The coordinate acquisition module is configured to acquire the real-time coordinates of the top of the boom. The modeling module is configured to build a trajectory model, which includes the rotation center axis of the turntable, the rotation center axis of the boom, the luffing plane of the boom, and the detection line along the extension direction of the boom. The data processing module is configured to rotate along the rotation center axis trajectory model, calculate the real-time coordinates of the top of the boom and the vertical distance between the boom and the luffing plane as the monitoring distance, and calculate the lateral curvature value through the monitoring distance. In the trajectory model, the detection line rotates along the rotation center axis. The rotation angle of the detection line is the amplitude difference angle. The deflection is calculated by the real-time coordinates of the top of the crane arm, the detection line, and the lateral bending value.

14. A real-time monitoring device for a crane boom according to claim 13, characterized in that, The coordinate acquisition module includes a first coordinate acquisition device, a second coordinate acquisition device and a third coordinate acquisition device. The first coordinate acquisition device is set on the turntable of the crane, the third coordinate acquisition device is set at the top of the boom, and the second coordinate acquisition device is set at a specified distance from the bottom of the boom. The steps for building a trajectory model in the modeling module are as follows: Rotate the turntable to collect the coordinate trajectories of the first coordinate acquisition device and the second coordinate acquisition device, calculate the center of the trajectory circle, and obtain the rotation center axis of the turntable based on the trajectory center and the trajectory normal vector; The crane boom luffing is controlled by acquiring the coordinate trajectory of the third coordinate acquisition device, calculating the trajectory center, and obtaining the coordinate trajectory center and trajectory normal vector. The rotation center axis of the crane boom; The boom is luffing. A luffing plane is drawn through the reference point, parallel to the coordinate trajectory of the third coordinate acquisition device. The distance between the coordinates of the third coordinate acquisition device and the luffing plane is collected as the foundation side bending distance. The crane boom extends, and the coordinate trajectory of the third coordinate acquisition device is used as the detection line.

15. A real-time monitoring device for a crane boom according to claim 13, characterized in that, The steps for the data processing module to calculate the lateral bending value are as follows: Collect the real-time coordinates of the first coordinate acquisition device, and rotate the model along the rotation center axis to make the real-time coordinates of the first coordinate acquisition device coincide with the amplitude plane; The real-time coordinates of the third coordinate acquisition device are collected, and the vertical distance between the real-time coordinates of the third coordinate acquisition device and the amplitude plane is calculated as the monitoring distance. The side curvature value is obtained by subtracting the foundation side curvature distance from the monitoring distance.

16. An electronic device comprising a processor and a memory communicatively connected to the processor and used for storing processor-executable instructions, characterized in that: The processor is used to execute the method described in any one of claims 1-12.

17. A server, characterized in that: The method includes at least one processor and a memory communicatively connected to the processor, the memory storing instructions executable by the at least one processor, the instructions being executed by the processor to cause the at least one processor to perform the method as described in any one of claims 1-12.

18. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by a processor, it implements the method described in any one of claims 1-12.

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