A remote control system and control method for cable cranes based on intelligent terminal devices

Abstract

This invention discloses a remote control system and method for cable cranes based on mobile devices, including a 4G control tablet, an industrial computer, a centralized control PLC system, a hoist substation PLC system, and a hoisting actuator. The 4G control tablet establishes a communication connection with the industrial computer via a 4G / 5G wireless network and with the centralized control PLC system via Ethernet. The centralized control PLC establishes a communication connection with the hoist substation PLC system via an industrial bus. The hoist substation PLC system is electrically connected to the hoisting actuator. The 4G / 5G control smart terminal device has a built-in control APP. This invention, by constructing a hierarchical control architecture, realizes remote wireless precise control and two-way real-time data interaction of cable cranes, improving operational safety and efficiency, while also possessing strong scalability to adapt to various operational needs.

Description

Technical Field

[0001] This invention relates to the field of cable crane control technology, specifically to a cable crane remote control system and control method based on mobile communication and hierarchical control architecture. It is applicable to cable crane operations in scenarios such as bridge engineering, port loading and unloading, and large component hoisting, and belongs to the field of industrial automation control equipment technology. Background Technology

[0002] Cable cranes, as large lifting and hoisting equipment, are widely used in bridge construction across mountains, rivers, and canyons, as well as in the transfer of large components. Traditional cable crane control methods are mainly divided into two categories: on-site control console control and wired remote control, both of which have several technical shortcomings. 1. Limited operating distance: On-site control consoles require operators to be on duty near the equipment, and the work area is often in dangerous environments such as high altitudes and near edges, which can easily lead to safety accidents; wired remote control is limited by cable length, the wiring is cumbersome and easily interfered with by construction, and has poor adaptability.

[0003] 2. Data interaction is not intuitive: Existing wireless remote controls mostly use dedicated remote controls with limited functions. They can only issue simple operation commands and cannot provide real-time feedback on key operating statuses such as winch speed, rope length, load, and motor current. Operators find it difficult to accurately judge the equipment's operating condition.

[0004] 3. Poor system stability and scalability: The dedicated remote controller uses point-to-point communication, which has weak anti-interference ability and cannot be adapted to the coordinated control of multiple hoists; it lacks an intermediate data forwarding and scheduling unit, and command transmission and status feedback are prone to delays or loss, affecting the accuracy of operation.

[0005] With the maturity of mobile communication technology and the widespread adoption of industrial smart terminals, remote equipment control via smart terminal devices has become a trend in industrial automation. Currently, there is no mature hierarchical collaborative control solution in the industry that combines "smart terminal devices + industrial control computer + PLC," which cannot simultaneously address the safety, real-time performance, and flexibility of remote cable crane operation, and thus fails to meet the demands of modern construction for efficient and safe operation. Therefore, there is an urgent need to develop a new type of remote control system for cable cranes to address the pain points of existing technologies. Summary of the Invention

[0006] Therefore, this invention aims to overcome the shortcomings of existing cable crane control technologies, such as limited operating distance, low safety, non-real-time status feedback, and poor system stability, and provides a remote control system and method for cable cranes based on mobile devices. By constructing a hierarchical control architecture, it achieves remote wireless precise control of cable cranes and two-way real-time data interaction, improving operational safety and efficiency, while also possessing strong scalability to adapt to various operational scenarios.

[0007] This invention is implemented as follows: a remote control system for cable cranes based on intelligent terminal devices is constructed, characterized by comprising a 4G control tablet, an industrial computer, a centralized control PLC system, a hoist substation PLC system, and a hoisting actuator; the 4G control tablet establishes a communication connection with the industrial computer via a 4G / 5G wireless network; the industrial computer has a built-in dedicated data forwarding system and establishes a communication connection with the centralized control PLC system via Ethernet; the centralized control PLC establishes a communication connection with the hoisting substation PLC system via an industrial bus; and the hoisting substation PLC system is electrically connected to the hoisting actuator. The 4G / 5G control smart terminal device has a built-in control APP for issuing operation commands and receiving and displaying device operating status data; the data forwarding software is used to realize bidirectional data forwarding, parsing, and format conversion between the 4G / 5G control smart terminal device and the centralized control PLC system; the centralized control PLC system is used for command parsing, scheduling, and status data aggregation; the hoist substation PLC system is used to drive the hoist actuator and collect device operating status data.

[0008] According to the system of the present invention, the 4G / 5G control smart terminal device is an industrial-grade rugged tablet (other Android system devices are optional), which supports 4G / 5G full network communication, has an IP65 or higher dustproof and waterproof rating, and is suitable for harsh environments at construction sites; the control APP has a visual operation interface and a status display interface, supports the issuance of rope winding, rope unwinding, and emergency stop commands, and real-time display of rope speed, current, rope length, and load parameters.

[0009] According to the system of the present invention, the bidirectional forwarding function of the data forwarding software includes: during uplink forwarding, receiving instructions issued by the 4G / 5G control smart terminal device and parsing them into industrial control codes recognizable by the centralized control PLC; during downlink forwarding, receiving status data uploaded by the centralized control PLC system and encapsulating it into a format recognizable by the 4G / 5G control smart terminal device. The data forwarding software has a built-in communication status monitoring module that triggers a local alarm when an abnormality occurs.

[0010] According to the system of the present invention, the industrial bus is a Profinet bus; the hoisting actuator includes a hoisting motor, a reducer, a brake, and a drum; the hoisting substation PLC is also electrically connected to a sensor group, which includes an encoder, a current sensor, and a position sensor, for collecting rope speed, motor current, and brake position status data.

[0011] A remote control method for cable cranes based on the above system includes the following steps: Step (1) System initialization: Turn on the power of each unit, complete the self-test and communication link establishment of the intelligent terminal equipment, industrial computer, centralized control PLC system and hoisting substation PLC system, and ensure that each unit is in a ready state; Step (2) Instruction issuance: The operator inputs the operation instruction through the smart terminal device APP, and the instruction is transmitted to the industrial control computer via 4G wireless network encryption; Step (3) Data forwarding and parsing: The industrial control computer parses the instructions and converts them into industrial control codes through the data forwarding software, and forwards them to the centralized control PLC system; the centralized control PLC system parses the instructions and generates execution instructions, which are then sent to the hoisting substation PLC system through the industrial bus; Step (4) Action execution: The PLC system of the hoisting substation drives the hoisting actuator to start and complete the corresponding rope winding or unwinding action; Step (5) Status Acquisition and Feedback: The hoisting substation PLC system collects equipment operating status data through the sensor group and uploads it to the centralized control PLC system; the centralized control PLC system summarizes the data and uploads it to the industrial computer, which then encapsulates and converts it through data forwarding software before sending it to the intelligent terminal device; Status monitoring: The smart terminal device APP displays status data in real time, and operators adjust operation instructions based on feedback to form a closed-loop control.

[0012] According to the method described in this invention, logical verification is added to the instruction parsing process in step (3) to ensure the legality of the instruction; the status data feedback frequency in step (5) is not less than 1 time / second to ensure real-time performance.

[0013] According to the method described in this invention, it is characterized by further including a fault protection step: when the sensor group collects overload, overtravel, or abnormal motor current data, the hoisting substation PLC system immediately drives the brake to stop the machine, and at the same time uploads the fault signal to the intelligent terminal device, triggering a pop-up alarm on the APP.

[0014] The present invention has the following advantages: 1. Improve operational safety: Operators can remotely control equipment from a safe location away from hazardous work areas using smart terminal devices, avoiding the risks of working at heights or near edges, and reducing the accident rate from the source; at the same time, real-time status feedback can promptly detect equipment abnormalities, facilitating quick issuance of stop commands and improving operational reliability.

[0015] 2. Overcoming distance limitations and enhancing flexibility: Relying on 4G / 5G networks to achieve wireless remote control, it is not restricted by cable length or operating range, and is suitable for the cross-regional hoisting needs of large-scale projects; the industrial-grade tablet is highly portable, and operators can flexibly adjust the monitoring position to adapt to complex construction site environments.

[0016] 3. Two-way data interaction for precise control: Through the industrial control computer data forwarding software and PLC hierarchical control, two-way real-time transmission of operation commands and status data is realized. Operators can precisely adjust the operation according to parameters such as rope speed and load, thereby improving hoisting accuracy and work efficiency.

[0017] 4. High system stability and strong anti-interference capability: Adopting a hybrid "wireless + wired" communication architecture, the wireless communication between the intelligent terminal equipment and the industrial control computer is adapted to the signal environment of the industrial site, while the wired communication between the industrial control computer and the PLC and between the PLC ensures stable data transmission and avoids instruction loss or delay; the layered architecture can realize fault isolation, and the failure of a single unit will not affect the operation of the overall system, thus improving fault tolerance.

[0018] 5. Highly scalable and adaptable to various scenarios: The smart terminal device APP can be flexibly upgraded to support collaborative control of multiple winches; the PLC and industrial control computer support multiple protocol compatibility and can be adapted to different models of winches and sensors, facilitating subsequent system expansion and function expansion, and adapting to cable crane operations in various scenarios such as bridges, ports, and factories. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the cable crane remote control system of the present invention. Detailed Implementation

[0020] The following will be combined with the appendix Figure 1 This invention will be described in detail, and the technical solutions in the embodiments of this invention will be clearly and completely described. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0021] Example 1: This invention provides an improved remote control system for cable cranes based on intelligent terminal devices, including a 4G control tablet, an industrial control computer data forwarding unit, a centralized control PLC, a hoist substation PLC, and a hoisting actuator. Each unit establishes a communication link in sequence to form a closed-loop control system, as shown in the following specific structure: 1. Smart terminal devices (tablets or mobile phones) As a remote human-machine interface terminal, it uses an industrial-grade rugged tablet (dustproof, waterproof, and impact-resistant, suitable for harsh construction site environments), with a built-in IoT 4G / 5G SIM card and a customized cable crane control APP. Operators can issue commands for winch reeling in, releasing, and emergency stopping via the APP's visual interface; simultaneously, it receives equipment operating status data and displays key parameters such as rope speed, rope length, motor current, brake status, and load in real time, achieving integrated operation and status monitoring. The intelligent terminal device establishes a stable wireless communication link with the industrial control computer via the 4G / 5G public network, overcoming spatial distance limitations.

[0022] 2. Industrial computer data forwarding unit: Deployed within a field control box, it utilizes an embedded industrial computer (low power consumption, high stability, suitable for long-term operation in industrial environments) and incorporates dedicated, customized data forwarding software. This software includes pre-defined bidirectional data forwarding rules and communication protocol conversion logic, with core functions including: Uplink data forwarding: Receives operation instructions from intelligent terminal devices, parses, verifies, and converts them into industrial control codes that can be recognized by the centralized control PLC, and forwards them to the centralized control PLC via Ethernet link; Downlink data forwarding: Receives equipment status data (including action information fed back by the hoist substation PLC and sensor data) uploaded by the centralized control PLC, summarizes, encapsulates and converts the data to a format suitable for the data reception format of the smart terminal device APP, and forwards it to the tablet via 4G / 5G network to achieve real-time data transmission.

[0023] 3. Centralized control PLC: As the core control and scheduling unit of the system, an industrial-grade PLC (such as the Siemens S7-1500, which has strong anti-interference capabilities and multi-protocol compatibility) is selected. It establishes wired communication with the industrial control computer via Ethernet and a communication connection with the hoist substation PLC via an industrial bus (Profinet). Its core functions are: receiving operation commands forwarded by the industrial control computer, performing secondary parsing and logical judgment, generating precise hoist control commands (including action type, speed parameters, and start / stop signals), and sending them to the hoist substation PLC via the industrial bus; simultaneously, it collects equipment operating status data uploaded by the hoist substation PLC, summarizes, filters, and performs preliminary processing, and then uploads it to the industrial control computer, realizing the integration of command scheduling and status aggregation.

[0024] 4. Hoisting substation PLC: Deployed next to the hoisting equipment, it uses a small industrial PLC (Siemens 1200, compact and suitable for field installation) to communicate with the centralized control PLC via an industrial bus, and is also electrically connected to the hoisting actuator and various sensors. Its core functions are: receiving control commands from the centralized control PLC, driving actuators such as frequency converters, relays, and electromagnetic brakes, and controlling the hoisting actuator to complete actions such as rope winding, rope unwinding, and stopping; simultaneously collecting data in real time such as hoisting motor current, speed, brake opening / closing status, and rope end position, processing the data, and feeding it back to the centralized control PLC, realizing simultaneous execution of actions and data acquisition.

[0025] 5. Hoisting actuator: As the terminal actuator, it includes a hoist motor, reducer, brake, drum, and matching transmission structure, and is electrically connected to the hoist substation PLC. It receives drive signals from the hoist substation PLC, uses the motor's forward and reverse rotation to achieve rope winding and unwinding actions, controls start and stop via the brake, and adjusts the rope speed via the reducer, precisely responding to operating commands. Simultaneously, it works with sensors to collect operating parameters, providing data support for status feedback.

[0026] Example 2: Based on the above system, the present invention also provides a remote control method for cable cranes, comprising the following steps: 1. Initialization preparation: Power on all units of the system. The intelligent terminal equipment, industrial computer, centralized control PLC, and hoist substation PLC complete self-test and communication link establishment to ensure normal communication of 4G network, Ethernet, and industrial bus, and that the sensors and actuators are in a ready state. 2. Command Issuance: Operators input target operation commands (such as rope winding, rope releasing, and gear parameters) through a smart terminal device APP. The commands are transmitted to the industrial control computer via a 4G / 5G network with encryption. 3. Data forwarding and parsing: The industrial control computer's data forwarding software receives instructions, performs parsing, verification, and format conversion, converting them into control codes recognizable by the centralized control PLC, and forwards them to the centralized control PLC via Ethernet; the centralized control PLC receives and parses the instructions, generates execution instructions adapted to the hoist substation PLC, and sends them out via the industrial bus; 4. Action execution: The PLC of the hoisting substation receives the execution command and drives the hoisting actuator to start. Through the coordinated work of the motor, reducer and brake, the corresponding rope winding or unwinding action is completed. 5. Status Feedback: The hoist substation PLC collects the operating status data of the actuator (cable force, gear position, etc.) through sensors and uploads it to the centralized control PLC in real time; the centralized control PLC summarizes the data and uploads it to the industrial control computer. 6. Status Display: The industrial control computer's data forwarding software encapsulates and converts the status data, then sends it to the smart terminal device via the 4G / 5G network. The APP interface displays various parameters in real time, and operators adjust operation commands based on status feedback, forming a closed-loop control.

[0027] Figure 1 This is a schematic diagram of the cable crane remote control system of the present invention. Status data is transmitted back along the reverse path, forming a closed-loop control; communication delay between units is ≤500ms, and packet loss rate is ≤0.1%. 1. Component Description: Each unit is a core component of the system. The sensor group is electrically connected to the hoisting substation PLC and is responsible for collecting data such as rope speed, motor current, and brake position to provide support for status feedback, consistent with the descriptions in the "Hoisting Substation PLC" and "Sensors and Actuators" sections. 2. Communication Links: Clearly define the communication methods and protocols for each unit—the intelligent terminal equipment and the industrial control computer use a 4G / 5G wireless network (AES encryption), the industrial control computer and the centralized control PLC use Ethernet (TCP / IP), and the centralized control PLC and the hoisting substation PLC use an industrial bus (Siemens S7 protocol), which fully matches the communication configuration in "Hardware Selection and Deployment" to ensure stable data transmission; 3. Data flow: Arrows clearly indicate the downward path of instructions (intelligent terminal device → industrial computer → centralized control PLC → hoisting substation PLC → actuator) and the upward path of status (actuator → hoisting substation PLC → centralized control PLC → industrial computer → intelligent terminal device), forming a closed-loop control, which echoes the bidirectional data interaction logic in the "technical solution"; 4. Key parameters: Communication latency ≤500ms, packet loss rate ≤0.1%, consistent with the link debugging indicators in "System Debugging and Operation", enhancing the system's feasibility and operability.

[0028] 1. Component Description: Each unit in the diagram is a core component of the system. The sensor group is integrated with the hoisting substation PLC to provide data support for status feedback, consistent with the description in the "Hoisting Substation PLC" section of the main text. 2. Communication Link: Clearly define the communication methods and protocols between each unit, ensuring they fully correspond to the communication link configuration in the "Specific Implementation Methods" section, and guaranteeing stable and reliable data transmission; 3. Data Flow: The arrows clearly distinguish the downward command path and the upward status path, forming a closed-loop control, echoing the description of two-way data interaction in the "Technical Solution" section of the main text; 4. Key parameters: Supplement core indicators such as communication latency and packet loss rate, align with the debugging requirements in the main text, and strengthen the explanation of system feasibility.

[0029] The specific implementation methods of this application are described below. Hardware selection and deployment 1. Smart terminal equipment: It adopts an Android rugged industrial tablet with a 10-inch touch screen, supports 4G full network access and WiFi dual-mode communication, has a built-in Android 10.0 system, and has an IP65 dustproof and waterproof rating, making it suitable for harsh construction site environments; it has a built-in IoT 4G / 5G card and uses an industrial-grade data plan from a carrier to ensure communication stability.

[0030] 2. Industrial PC: A Lenovo industrial PC is selected, equipped with a third-generation i5 processor, 16GB of memory, and a 500GB solid-state drive. It supports Windows 11 Professional and has multiple serial and network ports for expansion. It is deployed in a field control box and connected to a 220V industrial power supply.

[0031] 3. PLC equipment: The centralized control PLC uses a Siemens S7-1500 CPU and supports Ethernet communication; the hoist substation PLC uses a Siemens S7-1200 CPU, equipped with digital input / output modules and analog acquisition modules, and is compatible with sensor data acquisition and actuator drive.

[0032] 4. Sensors and actuators: Incremental encoders are used to collect rope speed and rope length data, Hall current sensors are used to collect motor current, and proximity switches are used to collect brake position status; the actuators are frequency converters (to control motor speed), electromagnetic brakes, and relays, which are electrically connected to the hoisting substation PLC.

[0033] 5. Communication Link Configuration: The intelligent terminal device communicates with the industrial control computer via a 4G / 5G network, enabling encrypted data transmission (using the AES encryption algorithm); the industrial control computer and the centralized control PLC establish an Ethernet connection via an RJ45 network cable, using Siemens' proprietary S7 communication protocol; the centralized control PLC and the hoist substation PLC are connected via a network cable to ensure real-time performance.

[0034] Software system development and configuration are as follows; 1. Smart terminal device APP: Developed based on Android Studio, the interface includes an operation area (rope retraction, rope release, and stop buttons, gear adjustment slider), a status display area (gear, cable tension, and other parameter information), and an alarm area (abnormal status pop-up prompts); it supports encrypted command sending and real-time data refresh (refresh frequency 1 time / second), and is compatible with industrial tablet touch operation.

[0035] 2. Industrial PC Data Forwarding Software: Developed based on Visual Studio and using the JAVA programming language, it supports MQTT and S7 communication protocol conversion; it has preset data parsing rules and can recognize the tablet APP instruction format and PLC control code format to achieve seamless bidirectional data forwarding; it has a built-in communication status monitoring module that triggers a local alarm (indicator light flashing) when there is an abnormality.

[0036] 3. PLC Programming: Siemens TIA Portal software is used to program the centralized control PLC, realizing instruction parsing, logic judgment, and data aggregation functions; TIA Portal software is used to program the hoist substation PLC, realizing motor drive, brake control, and sensor data acquisition functions; fault protection logic (such as automatic stop operation in case of overload or overtravel) is added to the program.

[0037] 4. System debugging and operation Standalone debugging: Perform power-on self-tests on each unit to verify the functions of the smart terminal device APP command issuance, industrial control computer software forwarding, PLC program logic, hoist actuator action, and sensor data acquisition accuracy, and eliminate standalone faults.

[0038] Link debugging: Build a complete communication link, test the data transmission latency (≤500ms) and packet loss rate (≤0.1%) of 4G network, Ethernet, and industrial bus, optimize communication parameters, and ensure link stability.

[0039] No-load test run: Control the winch to run under no-load conditions, test the response speed of rope winding and unwinding actions, verify the accuracy of real-time status data feedback, and adjust the speed adjustment precision to ensure that the actions are consistent with the commands.

[0040] Load testing: Simulate actual hoisting scenarios, conduct hoisting operations under different loads, test the system's stability and accuracy under load conditions, verify fault protection functions (such as automatic shutdown and alarm in case of overload), optimize control parameters, and ensure that actual operation requirements are met.

[0041] The social benefits and use value of this application are described below; I. Social Benefits (I) Cable crane operations are frequently used in large-scale engineering projects such as bridges, ports, and factories. In traditional operation modes, operators must operate the cranes at close range in dangerous areas such as high altitudes and near edges, posing extremely high safety risks. This patent utilizes 4G / 5G remote control technology, allowing operators to control the cranes from a safe area, spatially isolating them from core risks such as falls from heights and impacts from heavy objects, significantly reducing the accident rate at the source. Simultaneously, the system is equipped with real-time status monitoring, automatic shutdown in case of malfunctions, and pop-up alarm functions, enabling rapid response to potential hazards such as overload and abnormal current, reducing the risk of accidents escalating.

[0042] (II) Currently, some cable crane operations still rely on manual close-range operation, resulting in low efficiency, insufficient control precision, and passive risk management. This patent integrates technologies such as 4G / 5G wireless communication, PLC hierarchical control, and intelligent terminal APP visual management to construct an intelligent control architecture of "wireless + wired" hybrid communication, breaking through the technical bottlenecks of traditional cable crane operations. Its promotion and application will force the industry to eliminate outdated manual operation modes, promote the upgrading of cable crane equipment towards intelligence, remote operation, and precision, drive technological iteration in the construction machinery field, improve the overall technical level and core competitiveness of my country's construction industry, and align with the industrial development trend of intelligent manufacturing.

[0043] (III) Traditional cable crane operators are required to work long hours in noisy, dusty, and high-risk construction sites, resulting in high labor intensity and difficulty in ensuring occupational health. This patent, through a remote control mode, liberates operators from harsh working environments, allowing them to operate the cranes in a comfortable and safe environment via a smart terminal. This significantly improves the working conditions of frontline workers and reflects humanistic care. At the same time, intelligent operation places new demands on personnel skills, which will promote the optimization of the industry's employment structure, guide workers towards technical and managerial positions, and enhance the overall employment quality and job attractiveness of the industry.

[0044] (iv) Standardizing Operational Standards and Enhancing Industry Safety Management: The system achieves standardized control of cable crane operations through features such as APP-based visual operation, instruction logic verification, and full-process data traceability. Operators must issue instructions according to standardized procedures, avoiding safety hazards caused by human error. Simultaneously, equipment operating status data and operation instruction records can be stored in real time, facilitating traceability of the operation process by enterprises and regulatory departments, and strengthening safety supervision. This helps promote the establishment of unified intelligent operational standards in the industry, improve the overall standardization of safety management, reduce safety accidents caused by non-standard operations, and maintain public safety and order in the engineering construction field.

[0045] II. Use Value (i) This patent enables two-way real-time interaction between operation commands and status data. Operators can monitor core parameters such as rope speed, load, and current in real time via an APP, accurately adjust their work actions, avoid rework due to operational deviations, and significantly improve hoisting accuracy. Simultaneously, 4G / 5G wireless communication overcomes the limitations of cable length and operating range, adapting to the cross-regional hoisting needs of large-scale projects. The portability of the industrial-grade tablet also allows operators to flexibly adjust the monitoring position, adapting to complex construction sites and greatly improving operational flexibility and efficiency. Furthermore, the system's stable layered architecture reduces equipment downtime due to malfunctions, and the automatic fault protection function reduces the risk of equipment damage. Combined with the reduced material loss due to precise control, this effectively lowers enterprise construction costs.

[0046] (II) The system adopts an industrial-grade rugged flat panel with an IP65 or higher dustproof and waterproof rating, making it suitable for harsh construction site environments such as bridge construction, port loading and unloading, and factory hoisting. The PLC and industrial control computer support multi-protocol compatibility and can be adapted to different models of winches and sensors. The smart terminal APP can be flexibly upgraded to support collaborative control of multiple winches. This strong scalability allows the system to adapt to different operational needs without large-scale modifications. It is suitable for large-scale cross-regional projects as well as meeting the precise hoisting needs of small and medium-sized factories, significantly broadening the application range of cable crane equipment and improving the equipment's versatility and utilization rate.

[0047] (III) The system collects equipment operating status data in real time through a sensor array, with a feedback frequency of no less than once per second. Operators can monitor the equipment's operating status in real time, predict potential faults in advance, and achieve "preventive maintenance," avoiding downtime losses and high repair costs caused by sudden equipment failures. Simultaneously, the data forwarding software has a built-in communication status monitoring module that triggers local alarms in case of anomalies. The layered architecture enables fault isolation; a single unit failure does not affect the overall system operation, improving system fault tolerance and reducing maintenance difficulty and costs. Furthermore, full-process data recording facilitates data analysis of equipment operating status, optimizes maintenance plans, and extends equipment lifespan.

[0048] (iv) Traditional cable crane operations require multiple operators to work together, each responsible for control, monitoring, and command, resulting in high labor costs. This patent, through a visual APP interface, enables a single person to remotely complete the entire process, including issuing commands, monitoring status, and handling emergencies, simplifying the workflow and reducing the number of operators required. Furthermore, intelligent operation reduces reliance on operator experience; operators can be trained quickly and efficiently, reducing training costs and further improving the company's economic efficiency.

[0049] (V) The hybrid "wireless + wired" communication architecture balances flexibility and stability. 4G / 5G wireless communication adapts to the signal environment of industrial sites, while wired communication between the industrial control computer and the PLC ensures stable data transmission, preventing command loss or delay and ensuring continuous operation. In case of sudden failures, the system can quickly trigger shutdown protection and report fault information, facilitating timely troubleshooting by maintenance personnel and shortening downtime. Improved operational efficiency and reduced downtime effectively accelerate the overall project progress, helping companies complete construction tasks ahead of schedule and improving project delivery efficiency and market competitiveness.

[0050] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A remote control system for cable cranes based on intelligent terminal devices, characterized in that, The system includes a 4G control tablet, an industrial computer, a centralized control PLC system, a hoist substation PLC system, and a hoisting actuator. The 4G control tablet establishes a communication connection with the industrial computer via a 4G / 5G wireless network. The industrial computer has a built-in data forwarding system and establishes a communication connection with the centralized control PLC system via Ethernet. The centralized control PLC establishes a communication connection with the hoisting substation PLC system via an industrial bus. The hoisting substation PLC system is electrically connected to the hoisting actuator. The 4G / 5G control smart terminal device has a built-in control APP, which is used to issue operation commands and receive and display device operating status data; the data forwarding system is used to realize bidirectional data forwarding, parsing and format conversion between the 4G / 5G control smart terminal device and the centralized control PLC system. The centralized control PLC system is used for instruction parsing, scheduling, and status data aggregation; the hoist substation PLC system is used to drive the hoist actuator and collect equipment operating status data.

2. The system according to claim 1, characterized in that, The 4G / 5G control smart terminal device is an industrial-grade rugged tablet (other Android system devices are optional), which supports 4G / 5G full network communication, has an IP65 or higher dustproof and waterproof rating, and is suitable for harsh construction site environments; the control APP has a visual operation interface and a status display interface, supports the issuance of rope winding, rope unwinding, and emergency stop commands, and real-time display of rope speed, current, rope length, and load parameters.

3. The system according to claim 1, characterized in that, The bidirectional forwarding function of the data forwarding software includes: during uplink forwarding, receiving instructions issued by 4G / 5G control smart terminal devices and parsing them into industrial control codes recognizable by the centralized control PLC; during downlink forwarding, receiving status data uploaded by the centralized control PLC system and encapsulating it into a format recognizable by the 4G / 5G control smart terminal devices. The data forwarding software has a built-in communication status monitoring module that triggers a local alarm when an anomaly occurs.

4. The system according to claim 1, characterized in that, The industrial bus is a Profinet bus; the hoisting actuator includes a hoisting motor, a reducer, a brake, and a drum; the hoisting substation PLC is also electrically connected to a sensor group, which includes an encoder, a current sensor, and a position sensor, used to collect data on rope speed, motor current, and brake position status.

5. A remote control method for a cable crane based on the system described in any one of claims 1-4, characterized in that, Includes the following steps: Step (1) System initialization: Turn on the power of each unit, complete the self-test and communication link establishment of the intelligent terminal equipment, industrial computer, centralized control PLC system and hoisting substation PLC system, and ensure that each unit is in a ready state; Step (2) Instruction issuance: The operator inputs the operation instruction through the smart terminal device APP, and the instruction is transmitted to the industrial control computer via 4G wireless network encryption; Step (3) Data forwarding and parsing: The industrial control computer parses the instructions and converts them into industrial control codes through the data forwarding software, and forwards them to the centralized control PLC system; the centralized control PLC system parses the instructions and generates execution instructions, which are then sent to the hoisting substation PLC system through the industrial bus; Step (4) Action execution: The PLC system of the hoisting substation drives the hoisting actuator to start and complete the corresponding rope winding or unwinding action; Step (5) Status Acquisition and Feedback: The hoisting substation PLC system collects equipment operating status data through the sensor group and uploads it to the centralized control PLC system; the centralized control PLC system summarizes the data and uploads it to the industrial computer, which then encapsulates and converts it through data forwarding software before sending it to the intelligent terminal device; Status monitoring: The smart terminal device APP displays status data in real time, and operators adjust operation instructions based on feedback to form a closed-loop control.

6. The method according to claim 5, characterized in that, In step (3), logical verification is added to the instruction parsing process to ensure the legality of the instruction; in step (5), the status data feedback frequency is not less than 1 time / second to ensure real-time performance.

7. The method according to claim 5, characterized in that, It also includes fault protection steps: when the sensor group collects overload, overtravel, or abnormal motor current data, the hoisting substation PLC system immediately drives the brake to stop the machine, and at the same time uploads the fault signal to the intelligent terminal device, triggering a pop-up alarm on the APP.

Images