A cable crane automatic hoisting system and method based on Beidou high-precision positioning

Abstract

The application discloses a cable crane automatic hoisting system and method based on Beidou high-precision positioning, and the system comprises a Beidou high-precision positioning module, a main control PLC, a substation PLC, a hoist mechanism, a safety sensor and a man-machine interface. The method comprises the following steps: positioning a lifting tool in a centimeter level through the Beidou module; performing workpiece coordinate conversion and intelligent path planning; the main control PLC drives the substation PLC and the hoist according to the planned path and real-time positioning feedback through a closed-loop control algorithm, so that the automatic and accurate movement of the lifting tool is realized; and meanwhile, multiple safety protections such as cable force overrun and positioning signal interruption are integrated. The application realizes the full automation and high-precision operation of cable hoisting, and significantly improves the construction efficiency, installation precision and operation safety.

Description

Technical Field

[0001] This invention relates to the field of automated control of construction machinery, specifically to an automatic hoisting system and method for cable cranes used in the construction of large-scale projects such as bridges and ports. Background Technology

[0002] Traditional cable hoisting operations rely heavily on the experience of the operators, using visual observation and manual operation of winches to move and position the lifting equipment. This method has the following significant drawbacks: 1. Low positioning accuracy: It is difficult to achieve precise alignment of components, especially large and heavy components, resulting in low installation efficiency and potential safety hazards.

[0003] 2. Low degree of automation: The entire process requires manual operation, which is labor-intensive, requires high skill levels from operators, and is prone to errors due to fatigue.

[0004] 3. Safety relies on manual judgment: Monitoring of cable tension, equipment status, etc. is discontinuous and inaccurate, and the early warning and protection capabilities are limited.

[0005] 4. Poor data traceability: Data from the hoisting process is difficult to record and analyze completely, which is not conducive to construction management and process optimization.

[0006] Although some existing hoisting equipment uses encoders or ordinary GPS for position feedback, their positioning accuracy (usually at the meter level) is far from meeting the requirements for centimeter-level hoisting and docking of large precision components. Furthermore, their stability is insufficient in complex construction environments, and there is a lack of systematic, fully closed-loop automatic control solutions based on high-precision real-time positioning. Summary of the Invention

[0007] Therefore, the present invention aims to overcome the shortcomings of the prior art and provide an automatic cable hoisting system and method based on Beidou high-precision positioning, so as to realize full automation, high-precision positioning, intelligent path planning and multiple safety protections in the hoisting process, thereby improving the efficiency, accuracy and safety of hoisting operations.

[0008] This invention is implemented by constructing an automatic cable hoisting system based on BeiDou high-precision positioning, characterized by comprising: The high-precision positioning unit includes at least one set of Beidou high-precision positioning modules installed on the lifting device, which are used to acquire the three-dimensional spatial coordinates of the lifting device in real time; Central control unit, including main control PLC; The distributed execution and sensing unit includes at least two substation PLCs, a hoisting electromechanical mechanism controlled by the substation PLCs, and safety sensors; the signal output terminal of the Beidou high-precision positioning module is connected to the main control PLC. The data interaction network allows the main control PLC and each of the substation PLCs to interact with each other in real time via industrial Ethernet or fieldbus. A human-machine interface is connected to the main control PLC; the main control PLC is configured to execute an automatic hoisting control program to realize the automatic movement and positioning of the hoisting device from the starting point to the target workpiece point.

[0009] The cable crane automatic hoisting system based on BeiDou high-precision positioning according to the present invention is characterized in that the BeiDou high-precision positioning module adopts carrier phase differential technology, and its positioning accuracy is at the centimeter level.

[0010] The cable crane automatic hoisting system based on Beidou high-precision positioning according to the present invention is characterized in that the safety sensors include cable force sensors, anemometers and / or lifting device tilt sensors, and the data of the safety sensors are collected by the substation PLC and uploaded to the main control PLC through the data interaction network.

[0011] An automatic hoisting method for cable cranes based on the above system, characterized in that it is executed by the main control PLC and includes the following steps: S1: Coordinate conversion steps: Obtain the design coordinates of the target workpiece, and combine the initial coordinates of the lifting device with the coordinates of the cable hoist fixed structure to establish the conversion relationship between the global coordinate system and the local control coordinate system of the winch; S2: Path planning steps: Automatically plan a smooth lifting path based on the starting coordinates of the lifting device and the target coordinates of the workpiece; S3: Closed-loop control steps: Generate the desired coordinate sequence based on the planned path, compare the desired coordinates with the actual coordinates fed back by the Beidou high-precision positioning module, calculate the position deviation, and calculate the speed control command for each winch motor based on the deviation. The winch motor mechanism is driven by the substation PLC to execute the command, so that the lifting device moves along the planned path. S4: Safety monitoring steps: During the entire hoisting process, monitor the cable tension, Beidou positioning signal status, work boundary and environmental parameters in real time. When any safety parameter exceeds the limit, trigger the corresponding protection action.

[0012] According to the method of the present invention, the triggering of the corresponding protection action in step S4 includes: when the cable force value exceeds the preset safety threshold, the main control PLC immediately sends an emergency stop command to all substation PLCs; when the Beidou positioning signal is detected to be lost or the accuracy is lower than the set value, the main control PLC controls the lifting device to slowly hover or operate in a downgraded safety mode, and issues an alarm signal.

[0013] According to the method of the present invention, in step S2, the path planning takes into account the obstacle avoidance area constraint and generates a smooth acceleration and velocity trajectory that meets the dynamic characteristics requirements of the winch system.

[0014] According to the method of the present invention, in step S3, the closed-loop control is executed cyclically with a fixed period of less than 200ms.

[0015] According to the method described in this invention, it is characterized by further including step S5: a data recording and traceability step, which records the position, speed, cable force, and alarm information data during the entire hoisting process and stores them in the main control PLC or upper-level database.

[0016] The present invention has the following advantages: High-precision automated hoisting: Utilizing centimeter-level BeiDou positioning technology combined with closed-loop control algorithms, the hoisting equipment achieves precise automatic positioning and movement, significantly reducing reliance on manual operation and improving installation accuracy and efficiency.

[0017] Intelligent path planning: Automatically generates the optimal hoisting path, improving operational efficiency and stability.

[0018] Comprehensive safety protection: It integrates multi-dimensional safety monitoring and interlocking protection such as cable tension, positioning signals, electronic fences, and environment, and builds an active safety protection system, which greatly improves the safety of operation.

[0019] The system boasts high integration and reliability: It adopts a distributed control architecture of "main control PLC + substation PLC", which has a clear hierarchy, reliable data transmission, and convenient system expansion and maintenance.

[0020] Data traceability: Data throughout the entire process is recorded and stored, which can be used for construction review, process optimization, and quality traceability. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall system architecture of this application.

[0022] In the diagram: 1-BeiDou high-precision positioning module, 2-lifting device, 3-main control PLC, 4-substation PLC, 5-hoisting electromechanical mechanism, 6-cable force sensor, 7-human-machine interface, 8-data interaction network. Detailed Implementation

[0023] 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.

[0024] Example 1: This invention provides an automatic cable hoisting system based on BeiDou high-precision positioning, comprising: High-precision positioning unit: includes at least one set of Beidou high-precision positioning modules installed on the lifting device, used to acquire the three-dimensional spatial coordinates of the lifting device in real time, with a positioning accuracy of centimeters.

[0025] Central control unit: including the main control PLC, which serves as the core of the system for data processing and command issuance. Distributed execution and sensing unit: includes at least two substation PLCs, a hoisting electromechanical mechanism, and various safety sensors. Each substation PLC controls its corresponding hoisting electromechanical mechanism and collects data from the safety sensors (such as cable tension sensors, anemometers, tilt sensors, etc.). The signal output of the BeiDou high-precision positioning module is connected to the main control PLC.

[0026] Data interaction network: The main control PLC and each of the substation PLCs interact with each other in real time via industrial Ethernet or fieldbus.

[0027] It is connected to the main control PLC and is used to input hoisting parameters, display system status, alarm information and hoisting trajectory.

[0028] The main control PLC integrates a control program for executing the following methods: Step S1: Lifting Initialization and Coordinate Conversion: Input the design 3D coordinates of the target workpiece through the human-machine interface. Based on the initial coordinates of the lifting device and the design coordinates of the workpiece measured by the Beidou high-precision positioning module, and combined with the coordinates of the fixed tower of the cable crane, the system establishes a conversion model between the global coordinate system of the lifting and the local control coordinate system of each winch.

[0029] Step S2: Intelligent Lifting Path Planning: Based on the coordinates of the lifting tool's starting point and the workpiece's target point, an optimal smooth movement path is automatically planned. The path planning considers obstacle avoidance areas, operational efficiency, and equipment dynamic characteristics, generating a trajectory sequence under speed and acceleration constraints.

[0030] Step S3: Automatic Lifting and Real-time Closed-Loop Control: The main control PLC calculates the desired coordinates of the lifting device at each moment in real time according to the planned path. The desired coordinates are compared with the actual coordinates of the lifting device fed back in real time by the Beidou high-precision positioning module to generate a position deviation. Based on the position deviation, the main control PLC calculates the speed control commands for each winch motor using a control algorithm (such as a PID algorithm). These speed control commands are sent to the corresponding substation PLCs via a data interaction network, and the substation PLCs drive the winch motor mechanisms to execute them, forming a closed-loop control of "positioning-comparison-calculation-execution," guiding the lifting device to automatically move along the planned path to the target point.

[0031] Step S4: Multiple safety protections during the hoisting process: Cable tension over-limit protection: Real-time monitoring of the cable tension value of each main cable. When the tension of any cable exceeds the preset safety threshold, the main control PLC immediately issues a stop command and alarms.

[0032] Positioning signal interruption protection: Continuously monitors the signal status of the BeiDou positioning module. When the signal is lost or the accuracy exceeds the tolerance, the system automatically switches to slow hovering or degrades operation according to the preset safety procedure and issues an alarm.

[0033] Boundary limit protection: An electronic fence is set in the control program. When the lifting equipment approaches or exceeds the set physical working boundary, the system automatically slows down or stops.

[0034] Multi-sensor fusion monitoring: By integrating data from sensors such as wind speed and hoist tilt angle, corresponding early warning or protection actions are triggered when environmental conditions or equipment status do not meet safety requirements.

[0035] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0036] like Figure 1 As shown, the system securely mounts a Beidou high-precision positioning module 1 on the lifting device 2 of the cable crane. This module uses carrier phase differential technology and can output real-time three-dimensional coordinates with an accuracy better than ±2cm. The main control PLC 3 is a large, high-performance PLC responsible for running the core control program. The substation PLCs 4 control the hoisting electromechanical mechanisms 5 that drive the load-bearing cable and the traction cable, respectively. The main and substation PLCs are connected via an industrial Ethernet switch.

[0037] The cable tension sensor 6 is installed at the cable anchoring end, and its signal is connected to the nearby substation PLC. The human-machine interface 7 is an industrial touch screen, which is connected to the main control PLC.

[0038] During operation, the operator inputs the target coordinates of the workpiece to be hoisted on touchscreen 7. The main control PLC 3 calls the pre-stored tower coordinates and combines them with the real-time acquired lifting device coordinates to complete the automatic coordinate system conversion. Based on the starting point and target point, the control program plans a smooth Bézier curve path that avoids obstacles.

[0039] During automatic operation, the main control PLC3 executes closed-loop control every 1000ms: it reads the BeiDou positioning coordinates, calculates the deviation from the desired point, performs PID calculations, and then sends a speed command to the substation PLC4. The substation PLC4 controls the motor driver to precisely adjust the winch speed.

[0040] Meanwhile, the safety protection threads run in parallel: if the cable force value reported by the substation PLC4 exceeds 100% of the rated value, the main control PLC3 immediately sends an emergency stop command; if the Beidou signal is continuously lost for more than 5 seconds, the control device will be suspended on the spot and an audible and visual alarm will be triggered.

[0041] The following section elaborates on the social benefits and application value of the cable crane automatic hoisting system based on BeiDou high-precision positioning in this application; I. Social Benefits (I) This system constructs a proactive safety protection system through comprehensive safety protection mechanisms such as cable tension monitoring, positioning signal verification, electronic fences, and multi-sensor fusion monitoring, significantly reducing the safety risks of hoisting operations from the source. Traditional cable hoisting relies on manual operation, which is prone to safety accidents such as lifting equipment deviation, cable tension exceeding limits, and equipment collisions due to visual deviations, operational errors, and environmental interference, resulting in personal injury and property damage. The closed-loop control and multi-interlock protection functions of this system can realize emergency responses such as immediate shutdown when cable tension exceeds limits, slow hovering when positioning signals are lost, and automatic deceleration when approaching boundaries, effectively avoiding various safety hazards, reducing the incidence of safety accidents, protecting the lives of construction personnel, reducing the waste of social resources and adverse social impact caused by accidents, and providing solid technical support for safe production in the engineering construction field.

[0042] (II) The system integrates cutting-edge technologies such as centimeter-level BeiDou positioning, distributed PLC control architecture, and intelligent path planning algorithms, breaking through the industry bottlenecks of traditional hoisting operations, which are characterized by "reliance on manual labor, limited precision, and uneven efficiency." Its automated hoisting and intelligent control modes drive the upgrade of cable crane hoisting from "manual operation" to "intelligent management and control," promoting technological iteration in related industries such as engineering machinery equipment, engineering construction, and automation control. Simultaneously, standardized control processes and traceable full-process data provide a technical basis for the industry to establish unified hoisting operation standards and quality evaluation systems, helping the industry to move away from experience-based dependence and towards standardized, refined, and intelligent development.

[0043] (III) Traditional cable hoisting demands extremely high skill levels and experience from operators, and the working environment is harsh (high altitude, open air, and frequent interference), resulting in high labor intensity. This system, through high-precision automated control, significantly reduces reliance on manual operation, decreases the need for manual labor in high-altitude and high-intensity work, and effectively alleviates the shortage of skilled operators in the engineering construction field. Simultaneously, operators can remotely monitor the work status through a human-machine interface, avoiding hazardous working environments, significantly improving working conditions, and reducing occupational health risks.

[0044] (iv) The core of the system adopts BeiDou high-precision positioning technology, replacing the potential dependence on foreign positioning systems and promoting the large-scale application of domestically developed core technologies in major engineering projects. The deep integration of BeiDou positioning technology not only improves the positioning accuracy and reliability of the hoisting system but also strengthens my country's technological self-reliance and controllability in infrastructure construction, avoiding the risks of project stagnation caused by foreign technological monopolies or signal interruptions. This is of significant strategic importance for ensuring the construction safety and stable progress of major national infrastructure projects (such as bridges, wind power, and water conservancy projects), and also expands the application scenarios for the industrialization of BeiDou technology.

[0045] II. Application Value (I) Major infrastructure construction: Improving construction efficiency and quality, and shortening construction period and costs: In the construction of major infrastructure projects such as bridges, high-rise buildings, water conservancy projects, and rail transit, cable-stayed crane installation is one of the core processes, requiring extremely high precision and efficiency. This system's centimeter-level positioning accuracy ensures precise alignment of components during installation, avoiding rework and rectification due to installation deviations, and significantly improving project quality. Its intelligent path planning function automatically generates optimal paths, avoiding obstacles and optimizing operating parameters. Compared to manual path planning, this significantly improves work efficiency and effectively shortens the construction cycle. Simultaneously, the high reliability and ease of maintenance of the distributed control architecture reduce equipment downtime and lower equipment operation and maintenance costs, ultimately achieving the core goals of "improving quality, increasing efficiency, and reducing costs" in engineering construction.

[0046] (II) New Energy and Heavy Equipment Sector: Adapting to Complex Scenarios and Expanding Lifting Boundaries In the construction of new energy projects such as wind power, photovoltaics, and nuclear power, hoisting operations often face challenges such as remote areas, high-altitude environments, large-tonnage components, and complex terrain. This system's comprehensive safety protection capabilities can adapt to the operational needs in harsh environments. Multi-sensor fusion monitoring can perceive environmental parameters such as wind speed and tilt angle in real time, ensuring operational stability. The automated hoisting function can accurately complete the hoisting and docking of high-precision components such as wind turbine blades, photovoltaic modules, and nuclear power equipment, avoiding the risk of errors caused by manual operation in complex scenarios. Furthermore, the system's scalability allows it to adapt to cable cranes of different tonnages and operating conditions, flexibly meeting the diverse hoisting needs of new energy projects, facilitating the large-scale deployment of the new energy industry, and providing technical support for achieving its goals.

[0047] (III) Industrial plants and port logistics: Achieving efficient management and control, and improving operational standardization: In scenarios involving the construction of large industrial plants, the installation of heavy equipment, and the hoisting of large cargo in ports, this system enables automated and precise transfer and installation of components / cargo. Its data traceability function comprehensively records data such as location, speed, cable force, and environmental conditions throughout the entire hoisting process, providing data support for cargo hoisting quality traceability and construction process optimization. This meets the stringent requirements of industrial production and port logistics for standardized and traceable operations. Simultaneously, automated control reduces efficiency fluctuations caused by human intervention, standardizes hoisting operations, improves plant construction progress and port logistics turnover efficiency, and enhances the stability and competitiveness of enterprise production operations.

[0048] (iv) Technology promotion and industrial empowerment: Creating a demonstration effect and driving the upgrading of the industrial chain: The system's technical architecture (BeiDou positioning + distributed PLC + closed-loop control + intelligent planning) can serve as a general solution, applicable to various lifting equipment such as tower cranes and crawler cranes, enabling intelligent upgrades across all types of lifting equipment. Simultaneously, the system's accumulated end-to-end lifting data can be combined with big data and artificial intelligence technologies to further optimize path planning algorithms and safety early warning models, forming a virtuous cycle of "technology application - data accumulation - algorithm iteration - performance improvement," empowering technological innovation for upstream and downstream enterprises in the engineering construction, equipment manufacturing, and automation control industries. Furthermore, the successful application of this system can serve as an industry demonstration case, encouraging more companies to increase investment in the research and application of intelligent lifting technology, thus driving technological upgrades and industrial transformation across the entire industry.

[0049] (V) Emergency Response and Disaster Relief: Enhancing rapid response capabilities and reducing disaster losses: In emergency rescue projects following natural disasters such as earthquakes, floods, and landslides, rapid and precise hoisting operations are crucial for road clearing, bridge repair, and the construction of temporary facilities. This system's automated hoisting capabilities significantly reduce preparation time, its intelligent path planning quickly adapts to complex terrain at rescue sites, and its comprehensive safety protection ensures the safety of rescue operations in unstable environments. It assists rescue teams in efficiently completing tasks such as transferring relief supplies, dismantling and replacing damaged components, enhancing the rapid response capability of emergency rescue efforts, minimizing loss of life and property, and providing strong technical support for emergency rescue work.

[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. An automatic cable hoisting system based on BeiDou high-precision positioning, characterized in that, include: The high-precision positioning unit includes at least one set of Beidou high-precision positioning modules installed on the lifting device, which are used to acquire the three-dimensional spatial coordinates of the lifting device in real time; Central control unit, including main control PLC; The distributed execution and sensing unit includes at least two substation PLCs, a hoisting electromechanical mechanism controlled by the substation PLCs, and safety sensors; the signal output terminal of the Beidou high-precision positioning module is connected to the main control PLC. The data interaction network allows the main control PLC and each of the substation PLCs to interact with each other in real time via industrial Ethernet or fieldbus. A human-machine interface is connected to the main control PLC; the main control PLC is configured to execute an automatic hoisting control program to realize the automatic movement and positioning of the hoisting device from the starting point to the target workpiece point.

2. The cable crane automatic hoisting system based on BeiDou high-precision positioning according to claim 1, characterized in that, The BeiDou high-precision positioning module uses carrier phase differential technology, and its positioning accuracy is at the centimeter level.

3. The cable crane automatic hoisting system based on BeiDou high-precision positioning according to claim 1, characterized in that, The safety sensors include cable tension sensors, anemometers, and / or lifting device tilt sensors. The data from the safety sensors are collected by the substation PLC and uploaded to the main control PLC through the data interaction network.

4. An automatic cable hoisting method based on the system described in any one of claims 1-3, characterized in that, Executed by the main control PLC, the following steps are included: S1: Coordinate conversion steps: Obtain the design coordinates of the target workpiece, and combine the initial coordinates of the lifting device with the coordinates of the cable hoist fixed structure to establish the conversion relationship between the global coordinate system and the local control coordinate system of the winch; S2: Path planning steps: Automatically plan a smooth lifting path based on the starting coordinates of the lifting device and the target coordinates of the workpiece; S3: Closed-loop control steps: Generate the desired coordinate sequence based on the planned path, compare the desired coordinates with the actual coordinates fed back by the Beidou high-precision positioning module, calculate the position deviation, and calculate the speed control command for each winch motor based on the deviation. The winch motor mechanism is driven by the substation PLC to execute the command, so that the lifting device moves along the planned path. S4: Safety monitoring steps: During the entire hoisting process, monitor the cable tension, Beidou positioning signal status, work boundary and environmental parameters in real time. When any safety parameter exceeds the limit, trigger the corresponding protection action.

5. The method according to claim 4, characterized in that, In step S4, the triggering of the corresponding protection action includes: when the cable force value exceeds the preset safety threshold, the main control PLC immediately sends an emergency stop command to all substation PLCs; when the Beidou positioning signal is detected to be lost or the accuracy is lower than the set value, the main control PLC controls the lifting device to slowly hover or operate in a downgraded safety mode and issues an alarm signal.

6. The method according to claim 4, characterized in that, In step S2, the path planning takes into account the obstacle avoidance area constraints and generates a smooth acceleration and velocity trajectory that meets the power characteristics requirements of the winch system.

7. The method according to claim 4, characterized in that, In step S3, the closed-loop control is executed cyclically with a fixed period of less than 200ms.

8. The method according to claim 4, characterized in that, It also includes step S5: data recording and traceability, which records the position, speed, cable force, and alarm information data throughout the hoisting process and stores them in the main control PLC or upper-level database.

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