A gantry crane steady state control system

Abstract

The application discloses a kind of portal crane steady control system, comprising: wire rope monitoring unit, vibration monitoring unit, wind monitoring unit, absolute value encoder module, self-locking control unit, drive unit, PLC control unit, generate the first control signal of hoisting mechanism, the action of hoisting mechanism is driven by drive unit;For based on the abnormal vibration degree of key position of portal crane structure, when generating the second control signal of inhibiting or eliminating the abnormal vibration of key position of portal crane structure, the action of luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of portal crane is controlled by drive unit;Based on the real-time wind direction angle of bulk cargo terminal operating environment, the real-time angle of slewing mechanism transmitted by absolute value encoder module is compared, and the third control signal is generated by real-time wind speed, control drive unit and self-locking control unit, realize adaptive control to portal crane slewing structure.

Description

Technical Field

[0001] This invention belongs to the technical field of gantry cranes and relates to a steady-state control system for gantry cranes. Background Technology

[0002] Gantry cranes are heavy-duty lifting equipment widely used in ports and shipyards. Their structural features include a tall portal frame and slewing, luffing, and hoisting mechanisms, enabling them to efficiently handle large-scale material handling tasks. Abnormal vibrations, wire rope breakage detection and prevention, and wind-resistant adaptive measures for the slewing mechanism significantly impact the safe and stable operation of gantry cranes. Therefore, there is an urgent need to develop a steady-state control system for gantry cranes to improve the efficiency and safety of equipment operation. Summary of the Invention

[0003] To solve the above problems, the technical solution adopted by the present invention is: a steady-state control system for a gantry crane, comprising:

[0004] Wire rope monitoring unit: used to monitor the amount of wire rope winding and unwinding in the hoisting mechanism, as well as the degree and location of wire rope breakage. Vibration monitoring unit: used to collect vibration signals from key structural parts of the gantry crane, process them, and determine whether there is abnormal vibration in the key structural parts of the gantry crane; Wind monitoring unit: Used to detect real-time wind speed and direction data in the operating environment of bulk cargo terminals; Absolute encoder module: used to detect the real-time angle of the rotary mechanism; Self-locking control unit: used for self-locking anchoring of the slewing structure of a pedestal crane; Drive unit: Used to control the movement of the luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of gantry crane; PLC control unit: Used to receive monitoring data transmitted by the wire rope monitoring unit on the wire rope winding and unwinding amount, wire rope breakage degree and breakage location of the hoisting mechanism, generate the first control signal of the hoisting mechanism, and drive the hoisting mechanism to move through the drive unit; Used to receive the abnormal vibration level of key parts of the gantry crane structure transmitted by the vibration monitoring unit, and when a second control signal is generated to suppress or eliminate the abnormal vibration of key parts of the gantry crane structure, the drive unit controls the movement of the luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of the gantry crane. Based on the real-time wind direction and angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit, the real-time angle of the slewing mechanism transmitted by the absolute encoder module, and the real-time wind speed, a third control signal is generated to control the drive unit and the self-locking control unit, thereby realizing adaptive control of the slewing structure of the pedestal crane.

[0005] Furthermore: the wire rope monitoring unit includes: Lifting absolute encoder: used to monitor the amount of wire rope wound up and down on the hoisting mechanism drum; Magnetic flux monitoring sensor for hoisting wire rope: used to collect the magnetic flux value of the hoisting wire rope at the rope outlet in the machine room; High-definition camera: used to capture image data of the hoisting mechanism wire rope between the top of the elephant trunk and the lifting device; Monitoring data exchange: used to receive and transmit the winding and unwinding amount of the hoisting mechanism drum wire rope transmitted by the hoisting absolute encoder, the magnetic flux value of the hoisting wire rope passing through the rope outlet of the machine room transmitted by the hoisting wire rope magnetic flux monitoring sensor, and the image data of the hoisting mechanism wire rope from the top of the elephant trunk to the lifting device transmitted by the high-definition camera. Wire rope monitoring server: Used to receive the winding and unwinding amount of the hoisting mechanism drum wire rope, the magnetic flux value of the hoisting wire rope passing through the rope outlet of the machine room, and the image data of the hoisting mechanism wire rope from the top of the elephant trunk beam to the lifting device transmitted by the monitoring data exchange. It uses magnetic flux detection method or machine vision recognition method to determine the degree of wire breakage and calculate the location of wire breakage.

[0006] Furthermore: the process of determining the degree of wire breakage in the wire rope using magnetic flux detection or machine vision recognition methods includes determining the degree of wire breakage based on magnetic flux detection, as detailed below: When 90%≤K 实际 / K 标准 When the percentage is less than 95%, it is determined that there is a minor breakage in the wire rope at this point. When K 实际 / K 标准 If the percentage is ≤90%, the wire rope is considered to have severe broken wires. Where: K 实际 K represents the magnetic flux of the wire rope passing the sensor. 标准 The standard magnetic flux of a brand new steel wire rope with no broken wires or damage; The process of determining the degree of wire breakage in a steel wire rope using magnetic flux detection or machine vision recognition methods also includes determining the degree of wire breakage based on machine vision recognition methods, as detailed below: When 110% > P 实际 / (0.5 (P 上 +P 下When the breakage rate is ≥105%, it is determined that there is a slight breakage in the wire rope at this point. When P 实际 / (0.5 (P 上 +P 下 When the breakage rate is ≥110%, it is determined that the wire rope has suffered severe wire breakage at this point. Where: P 实际 P represents the pixel value in the width direction of the wire rope of the lifting mechanism at each monitoring position from the top of the elephant trunk bridge to the lifting device. 上 The pixel value in the width direction of the steel wire rope at a position N cm above the current monitoring location is P. 下 The pixel value in the width direction of the steel wire rope at a current monitoring position N cm downwards.

[0007] Furthermore: the process of determining the location of the broken wire in the wire rope using magnetic flux detection or machine vision recognition methods includes calculating the location of the broken wire based on the magnetic flux detection method, as detailed below: When a minor or severe wire rope breakage is detected, the location of the broken wire rope is calculated starting from the connection point between the wire rope and the lifting device at the top. The specific formula is as follows: S1=HH 吊具 +L+S 当前 -S 初始 ; Where: H is the height position value of the lifting device in the lifting direction, H 吊具 The height of the lifting device is L, where L is the length of the wire rope from the top pulley of the elephant trunk beam to the magnetic flux monitoring sensor at the rope outlet in the machine room, and S is the height of the lifting device itself. 当前 S represents the current release of the hoisting wire rope detected by the hoisting absolute encoder. 初始 The amount of hoisting wire rope released is detected by the hoisting absolute encoder when the spreader is in the upper stop position; The process of determining the location of the broken wire in the wire rope using magnetic flux detection or machine vision recognition methods includes the following process of calculating the location of the broken wire based on machine vision recognition methods: When a minor or severe wire rope breakage is detected, the location of the broken wire rope is calculated starting from the connection point between the wire rope and the lifting device at the top. The specific formula is as follows: S2=(S 当前 -L) PH 断 / PH 顶 ; Wherein: S 当前 PH represents the current release of the hoisting wire rope detected by the hoisting absolute encoder, where L is the length of the wire rope from the top pulley of the elephant trunk beam to the magnetic flux monitoring sensor at the rope outlet in the machine room. 断PH represents the pixel value from the location of the broken wire in the wire rope to the top of the lifting device. 顶 The pixel value is the distance from the top pulley of the elephant trunk beam to the top of the lifting device.

[0008] Further: The process of receiving the first control signal of the hoisting mechanism transmitted by the PLC control unit and driving the operation of the hoisting mechanism is as follows: When a minor wire breakage occurs, an alarm signal is issued, and the hoisting mechanism of the gantry crane is controlled to operate at a speed limited to 50%. When a severe wire breakage occurs, a fault signal is issued, and the hoisting mechanism of the gantry crane is only allowed to exit the operation at a speed limited to 10% before the wire rope is replaced.

[0009] Furthermore: the vibration acquisition unit includes an elephant trunk bridge vibration acquisition subunit, a slewing bearing vibration acquisition subunit, and a sea-land side door leg vibration acquisition subunit; The elephant trunk bridge vibration acquisition subunit includes: The first vibration acquisition sensor is used to acquire vibrations at the pivot point at the root of the object's nose. The second vibration acquisition sensor is used to acquire the vibration of the No. 1 hinge point at the root of the object's nose. The third vibration acquisition sensor is used to acquire the vibration of the No. 2 hinge point at the root of the object's nose. The fourth vibration acquisition sensor is used to acquire vibration data at the #3 pivot point at the root of the object's nose. The fifth vibration acquisition sensor is used to acquire the vibration of the top pulley on the bridge of the nose of the object; The slewing bearing vibration acquisition subunit includes: The sixth vibration acquisition sensor: used to acquire the vibration of the slewing bearing; The vibration acquisition subunit for the land-sea side portal legs includes: The seventh vibration acquisition sensor is used to acquire vibration data of the first gate leg on the sea side. The eighth vibration acquisition sensor is used to acquire vibration data of the second leg on the sea side. Ninth vibration acquisition sensor: used to acquire vibration data of the first landside gate leg; The tenth vibration acquisition sensor: used to acquire vibration data of the second landside gate leg; The vibration acquisition subunit for the land-sea side trolley includes: The eleventh vibration acquisition sensor: used to acquire the vibration of the first vehicle on the sea side; The twelfth vibration acquisition sensor: used to acquire the vibration of the second vehicle on the sea side; The thirteenth vibration acquisition sensor: used to acquire the vibration of the first vehicle on the landside; The fourteenth vibration acquisition sensor: used to acquire the vibration of the second vehicle on the landside; The reducer vibration acquisition subunit includes: The fifteenth vibration acquisition sensor: used to acquire the vibration of the reducer of the amplitude transformer mechanism; The sixteenth vibration acquisition sensor is used to acquire vibration data from the reducer of the hoisting mechanism.

[0010] Furthermore: the process of generating a second control signal to suppress or eliminate the abnormal vibration of the key parts of the gantry crane structure based on the abnormal vibration level transmitted by the vibration monitoring unit is as follows: When the trolley mechanism of the gantry crane moves, the same abnormal vibration judgment method is used for the seventh to fourteenth vibration acquisition sensors, as follows: If 1.1 K 标准a >K 实际a ≥1.05 K 标准a The vibration acquisition sensor is used to determine whether the abnormal vibration of the corresponding key structural part has reached the alarm level. If K 实际a ≥1.1 K 标准a The abnormal vibration of the corresponding key structural parts monitored by the vibration acquisition sensor is determined to have reached the level of a fault. Where K 实际a K represents the vibration amplitude value monitored in real time by any one of the seventh to fourteenth vibration acquisition sensors; 标准a The vibration amplitude value of any one of the seventh to fourteenth vibration sensors during normal operation; When the luffing mechanism of the gantry crane is activated, the same anomaly detection method is used for the data from the first vibration acquisition sensor to the fifth vibration acquisition sensor and the fifteenth vibration acquisition sensor. If 1.1 K 标准b >K 实际b ≥1.05 K 标准b The vibration acquisition sensor is used to determine whether the abnormal vibration of the corresponding key structural part has reached the alarm level. If K 实际b ≥1.1 K 标准b The abnormal vibration of the corresponding key structural parts monitored by the vibration acquisition sensor is determined to have reached the level of a fault. Where K 实际bK represents the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (first to fifth and fifteenth vibration acquisition sensors); 标准b The vibration amplitude value of any one of the vibration acquisition sensors, from the first to the fifth and the fifteenth vibration acquisition sensors, during normal operation; When the hoisting mechanism of the gantry crane operates, the data from the first to the fifth vibration acquisition sensors and the sixteenth vibration acquisition sensor are monitored in real time. If 1.1 K 标准c >K 实际c ≥1.05 K 标准c The system determines that any one of the vibration acquisition sensors (first to fifth and fifteenth) has detected abnormal vibrations in the corresponding key structural parts, which has reached the alarm level. If K 实际c ≥1.1 K 标准c The abnormal vibration of the corresponding key structural part monitored by any one of the vibration acquisition sensors (first to fifth and fifteenth) reaches the level of a fault. Where: K 实际c K represents the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (first to fifth and fifteenth vibration acquisition sensors); 标准c The vibration amplitude value of any one of the vibration acquisition sensors, from the first to the fifth and the fifteenth vibration acquisition sensors, during normal operation; When the slewing mechanism of the gantry crane operates, the sixth vibration acquisition sensor is monitored in real time. If 1.1 K 标准d >K 实际d ≥1.05 K 标准d The system determines that the abnormal vibration of the corresponding key structural part monitored by the sixth vibration acquisition sensor has reached the alarm level. If K 实际d ≥1.1 K 标准d The abnormal vibration of the corresponding key structural part monitored by the sixth vibration acquisition sensor is determined to have reached the level of a fault. Where K 实际d K represents the vibration amplitude value monitored in real time by the sixth vibration acquisition sensor. 标准d This represents the vibration amplitude value when the sixth vibration acquisition sensor is operating normally.

[0011] Furthermore: the process of generating a control signal to suppress or eliminate the abnormal vibration of the key parts of the gantry crane structure based on the abnormal vibration level transmitted by the vibration monitoring unit is as follows: When the gantry crane's trolley mechanism reaches an alarm or fault level during its acceleration and deceleration phases, if the vibration amplitude value monitored in real-time by any of the seven to fourteenth vibration sensors reaches the alarm or fault level, the acceleration and deceleration values ​​of the trolley mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration and deceleration values ​​a of the trolley mechanism 大车调整 =K a a 大车 ; Where: K a The vibration suppression optimization coefficient for the acceleration and deceleration phases of the trolley mechanism is set to 0.8, a. 大车 These are the acceleration and deceleration values ​​before the adjustment of the trolley mechanism; When the gantry crane's trolley mechanism is running at a constant speed, and the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (seventh to fourteenth vibration acquisition sensors) reaches the alarm or fault level, the trolley mechanism's running speed will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted trolley mechanism operating speed value V 大车调整 =K A V 大车 The speed value corresponding to the vibration amplitude reaching the alarm or fault level will be added to the given speed shielding zone of the trolley mechanism. In subsequent operation of the trolley mechanism, the speed setpoint in the given shielding zone will be controlled according to the optimized and adjusted operating speed value. Where: K A The vibration suppression optimization coefficient for the trolley mechanism during uniform motion is set to 0.95. 大车 This refers to the operating speed value of the trolley mechanism before adjustment.

[0012] When the luffing mechanism of a gantry crane reaches an alarm or fault level in real-time monitoring by any one of the first to fifth vibration sensors or the fifteenth vibration sensor during its acceleration and deceleration phases, the acceleration and deceleration values ​​of the luffing mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration / deceleration values ​​a of the variable amplitude mechanism 变幅调整 =K b a 变幅 ; Where: K bThe vibration suppression optimization coefficient for the acceleration and deceleration phases of the amplitude-changing mechanism is set to 0.8, a. 变幅 These are the acceleration and deceleration values ​​of the luffing mechanism before adjustment. When the luffing mechanism of a gantry crane reaches an alarm or fault level during its uniform speed operation phase, if the vibration amplitude value monitored in real time by any one of the first to fifth vibration sensors or the fifteenth vibration sensor reaches the level required for an alarm, the operating speed of the luffing mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted operating speed value V of the luffing mechanism 变幅调整 =K B V 变幅 The speed value corresponding to the vibration amplitude reaching the alarm or fault level is added to the speed setpoint shielding zone of the luffing mechanism. In subsequent operation of the luffing mechanism, the speed setpoint in the setpoint shielding zone is controlled according to the optimized and adjusted operating speed value. Where: K B The vibration suppression optimization coefficient for the constant velocity motion phase of the amplitude-changing mechanism is set to 0.95. 变幅 This is the operating speed value of the luffing mechanism before adjustment.

[0013] When the hoisting mechanism of a gantry crane reaches an alarm or fault level during its acceleration and deceleration phase, if the vibration amplitude value monitored in real time by any one of the first to fifth vibration sensors or the sixteenth vibration sensor reaches the alarm or fault level, the PLC control unit will optimize and adjust the acceleration and deceleration values ​​of the hoisting mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted hoisting mechanism acceleration and deceleration values ​​a 起升调整 =K c a 起升 ; Where K c The vibration suppression optimization coefficient for the hoisting mechanism during acceleration and deceleration is set to 0.8, a. 起升 These are the acceleration and deceleration values ​​before the hoisting mechanism is adjusted.

[0014] Step 8: When the hoisting mechanism of the gantry crane reaches an alarm or fault level during its uniform speed operation phase, if any one of the vibration acquisition sensors (first to fifth and sixteenth vibration acquisition sensors) detects a vibration amplitude that triggers an alarm, the hoisting mechanism's operating speed will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted hoisting mechanism operating speed value V 起升调整 =K C V 起升The speed value corresponding to the vibration amplitude reaching the alarm or fault level will be added to the hoisting mechanism's operating speed setpoint shielding zone. Subsequently, when the hoisting mechanism is running, the speed setpoint in the setpoint shielding zone will be controlled according to the optimized and adjusted operating speed value. Where K C The vibration suppression optimization coefficient for the hoisting mechanism during uniform motion is set to 0.95. 起升 This is the operating speed value of the hoisting mechanism before adjustment.

[0015] When the slewing mechanism of a gantry crane reaches an alarm or fault level as monitored in real time by the sixth vibration acquisition sensor during its acceleration and deceleration phase, the acceleration and deceleration values ​​of the slewing mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration / deceleration values ​​a of the slewing mechanism 回转调整 =K d a 回转 ; Where K d The vibration suppression optimization coefficient for the acceleration and deceleration phases of the rotary mechanism is set to 0.8, a. 回转 These are the acceleration and deceleration values ​​before the adjustment of the slewing mechanism.

[0016] When the slewing mechanism of the gantry crane reaches an alarm or fault level as monitored in real time by the sixth vibration acquisition sensor during its uniform speed operation, the slewing mechanism's operating speed will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted operating speed value V of the slewing mechanism 回转调整 =K D V 回转 The speed value corresponding to the vibration amplitude reaching the alarm or fault level is added to the speed setpoint shielding zone of the slewing mechanism. In subsequent operation of the slewing mechanism, the speed setpoint in the setpoint shielding zone is controlled according to the optimized and adjusted operating speed value. Where: K D The vibration suppression optimization coefficient for the uniform motion phase of the rotary mechanism is set to 0.95, V. 回转 This is the operating speed value of the slewing mechanism before adjustment.

[0017] Furthermore: the process of comparing the real-time wind direction angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit, the real-time angle of the slewing mechanism transmitted by the absolute encoder module, and the real-time wind speed to generate a third control signal to control the third drive unit and the self-locking control unit, and adaptively controlling the slewing structure of the pedestal crane, is as follows: The real-time wind direction angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit is compared with the real-time angle of the slewing mechanism transmitted by the absolute encoder module: When the deviation between the minimum windward angle of the upper part of the gantry crane above the slewing structure and the wind direction angle is less than the threshold angle, no adaptive adjustment is required; When the minimum windward angle of the upper part of the gantry crane above the slewing structure deviates from the wind direction angle by ≥ the threshold angle, proceed to the next step; The self-locking control unit releases the electric anchoring device; The control drive unit performs adaptive adjustment control of the slewing angle according to the given value of the slewing damping correction until the slewing structure rotates to the adaptive ideal angle. During the adaptive adjustment of the slewing angle, when the slewing structure is subjected to wind force and the slewing angle exceeds the theoretical angle of the adaptive adjustment, the slewing inverter in the control drive unit outputs reverse damping control torque to prevent the slewing structure from rotating uncontrollably at high speed. The self-locking control unit anchors the electric anchoring device.

[0018] Furthermore, the calculation process for the given value of the slewing damping correction is as follows: The specific calculation method for determining the ideal windproof adaptive angle of a gantry crane is as follows: The reference is based on south as 0°, west as 90°, north as 180°, and east as 270°; When (Φ N -Φ 风 )<(Φ N+1 -Φ 风 When the ideal windproof angle Φ of the gantry crane is 0, 理想 For Φ N ; When (Φ N -Φ 风 )≥(Φ N+1 -ω 风 When the ideal windproof angle Φ of the gantry crane is 0, 理想 For Φ N+1 ; Where: Φ 风 Φ is the wind direction angle detected by the wind monitoring unit. N Φ is the angle of the nearest keyhole in the counterclockwise direction of the wind direction. N+1 The angle of the nearest keyhole in the clockwise direction of the wind direction; Based on the wind-resistant adaptive ideal angle of the gantry crane, the slewing angular velocity limit value is determined, and the calculation method of the slewing angular velocity limit value ω is as follows: ω=(2 β (Φ-Φ理想 )) 0.5 ; Where: β is the angular acceleration of the rotary mechanism, Φ is the real-time angle value of the rotary mechanism, Φ 理想 Ideal angle for wind protection and adaptive design of gantry cranes; The rotational damping is calculated based on the aforementioned rotational angular velocity limit ω, and the rotational damping correction setpoint ω 阻尼 The calculation formula is as follows: ω 阻尼 =((Φ-Φ 理论 ) / (Φ 理想 -Φ 起始 )) 0.5 ω Where: ω 阻尼 Φ represents the actual angle of the slewing mechanism. 理论 For the adaptive adjustment of the rotary mechanism, the corresponding theoretical angle, Φ 理想 For the ideal windproof adaptive angle of the gantry crane, Φ 起始 ω represents the initial angle before the adaptive adjustment of the slewing mechanism, and ω represents the angular velocity limit value for the adaptive adjustment of the slewing mechanism.

[0019] This invention provides a steady-state control system for gantry cranes. By equipping the gantry crane with devices for vibration monitoring and suppression, wire rope monitoring and breakage prevention, and wind-resistant adaptive slewing mechanism, the safety and stability of gantry crane operation are enhanced. The steady-state control system for gantry cranes is the core of ensuring safe and efficient operation of the equipment and is crucial for the efficient and stable operation of bulk cargo terminals.

[0020] This application has a simple structure, strong practicality, and high safety and reliability; it effectively avoids accidents caused by factors such as strong winds, broken wire ropes, and vibration. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a component layout diagram of the steady-state control system for a gantry crane; Figure 2 This is a diagram of the steady-state control system architecture for a gantry crane. Figure 3 This is the wiring diagram for the wire rope online monitoring device; Figure 4This is the wiring diagram for the online vibration monitoring device; Figure 5 This is the wiring diagram for the slewing windproof adaptive control unit; Figure 6 It is a UPS power supply device; Figure 7 This is the wiring diagram for the drive unit; Figure 8 This is the wiring diagram for the PLC control unit; Figure 9 This is the control flowchart of the steady-state control system for a gantry crane; Figure 10 This is the control flowchart of the online monitoring system for wire ropes of gantry cranes; Figure 11 This is the control flowchart of the online vibration monitoring system for gantry cranes; Figure 12 This is the control flowchart for the windproof adaptive device of a gantry crane.

[0023] Reference numerals: 1. Vibration monitoring unit; 2. PLC control unit; 3. Drive unit; 4. Vibration monitoring server; 6. First vibration acquisition sensor; 7. Second vibration acquisition sensor; 8. Third vibration acquisition sensor; 9. Fourth vibration acquisition sensor; 10. Fifth vibration acquisition sensor; 11. Sixth vibration acquisition sensor; 12. Seventh vibration acquisition sensor; 13. Eighth vibration acquisition sensor; 14. Ninth vibration acquisition sensor; 15. Tenth vibration acquisition sensor; 16. Eleventh vibration acquisition sensor; 17. Twelfth vibration acquisition sensor; 18. Thirteenth vibration acquisition sensor; 19. Fourteenth vibration acquisition sensor; 20. Fifteenth vibration acquisition sensor; 21. Sixteenth vibration acquisition sensor. 22. Sensor, PLC module, 23. Switch, 24. Luffing mechanism frequency converter, 25. Hoisting mechanism frequency converter, 26. Slewing mechanism frequency converter, 27. Trolley mechanism frequency converter, 28. Luffing mechanism motor, 29. Hoisting mechanism motor, 30. Slewing mechanism motor, 31. Trolley mechanism motor, 32. High-definition camera, 33. UPS power supply device, 34. Contactor for electric anchor lock control, 35. Electric anchoring device, 36. Wind power monitoring unit, 37. Hoisting wire rope magnetic flux monitoring sensor, 38. Wire rope monitoring unit, 39. Absolute encoder module, 40. Self-locking control unit. Detailed Implementation

[0024] It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] Steady-state control system for gantry cranes, such as Figure 2 As shown, it includes a PLC control unit 2, a drive unit 2, a slewing windproof adaptive control unit, and a status monitoring unit; The condition monitoring unit includes an online wire rope monitoring device and an online vibration monitoring device; like Figure 3 As shown, the wire rope online monitoring device includes a hoisting absolute encoder, a hoisting wire rope magnetic flux monitoring sensor 37, a wire rope monitoring server, a monitoring data exchange 23, and a high-definition camera 32. Lifting absolute encoder: used to monitor the amount of wire rope wound up and down on the hoisting mechanism drum; Magnetic flux monitoring sensor 37 for hoisting wire rope: used to collect the magnetic flux value of the hoisting wire rope at the rope outlet of the machine room; High-definition camera 32: Used to acquire image data of the hoisting mechanism wire rope between the top of the elephant trunk beam and the lifting device; Monitoring data exchange 23: is used to receive and transmit the winding and unwinding amount of the hoisting mechanism drum wire rope transmitted by the hoisting absolute encoder, the magnetic flux value of the hoisting wire rope passing through the rope outlet of the machine room transmitted by the hoisting wire rope magnetic flux monitoring sensor 37, and the image data of the hoisting mechanism wire rope from the top of the elephant trunk to the lifting device transmitted by the high-definition camera 32. Wire rope monitoring server: Used to receive the winding and unwinding amount of the hoisting mechanism drum wire rope, the magnetic flux value of the hoisting wire rope passing through the rope outlet of the machine room, and the image data of the hoisting mechanism wire rope from the top of the elephant trunk beam to the lifting device transmitted by the monitoring data exchange 23. It uses magnetic flux detection method or machine vision recognition method to determine the degree of wire breakage and calculate the location of wire breakage.

[0027] The hoisting absolute encoder transmits the monitored winding and unwinding amount of the hoisting mechanism drum wire rope to the wire rope monitoring server via the monitoring data exchange 23 using the TCP / IP protocol; the hoisting wire rope magnetic flux monitoring sensor 37 transmits the monitored magnetic flux value of the hoisting wire rope at the rope outlet of the machine room to the wire rope monitoring server via the monitoring data exchange 23 using the TCP / IP protocol. The high-definition camera 32 transmits the image data of the hoisting mechanism wire rope between the top of the elephant trunk beam and the lifting device to the wire rope monitoring server via the monitoring data switch 23 using the TCP / IP protocol. The wire rope monitoring server is used to process the received data to determine the degree and location of wire rope breakage throughout the entire stroke of the hoisting mechanism of the gantry crane, and transmits the data results to the PLC control unit 2 via the monitoring data switch 23 in the form of TCP / IP protocol.

[0028] Lifting absolute encoder: installed on the lifting mechanism drum in the machine room; Magnetic flux monitoring sensor 37 for hoisting wire rope: installed at the rope outlet in the machine room and looped onto the hoisting wire rope; High-definition camera 32: mounted on the top of the elephant's trunk.

[0029] like Figure 4 As shown, the vibration online monitoring device includes a vibration monitoring unit 1; The vibration monitoring unit 1 includes a vibration acquisition unit, a data acquisition device, and a vibration monitoring server 4; Vibration acquisition unit: used to acquire vibrations of key structural parts of the gantry crane; the key parts include the elephant trunk hinge point, slewing bearing, sea-land side gantry legs, sea-land side trolley, luffing mechanism reducer and hoisting mechanism reducer in the machine room. Data acquisition unit: used to transmit vibration signals from key structural parts acquired by the vibration acquisition unit; Vibration monitoring server 4: used to process the vibration signals of key structural parts transmitted by the data acquisition device, and to determine whether there is abnormal vibration in the key structural parts of the gantry crane.

[0030] The vibration acquisition unit includes: The vibration acquisition unit includes: Elephant Trunk Bridge Vibration Acquisition Subunit: Used for vibration acquisition of multiple parts of the object's trunk bridge; Slewing bearing vibration acquisition subunit: used for acquiring vibration data from slewing bearings; The vibration acquisition subunit for the land-sea side gate leg is used to acquire vibration data from multiple parts of the land-sea side gate leg. The vibration acquisition subunit of the land-sea side trolley is used to acquire vibration data from multiple parts of the land-sea side trolley. Reducer vibration acquisition subunit: used to acquire vibration data from multiple reducers; The elephant trunk bridge vibration acquisition subunit includes: First vibration acquisition sensor 6: used to acquire vibrations at the pivot point at the root of the object's nose; Second vibration acquisition sensor 77: used to acquire vibration at the #1 hinge point at the root of the object's nose; Third vibration acquisition sensor 8: used to acquire vibration at the #2 hinge point at the root of the object's nose; Fourth vibration acquisition sensor 9: used to acquire vibration at the 3# hinge point at the root of the object's nose; Fifth vibration acquisition sensor 10: used to acquire the vibration of the top pulley of the object's nose bridge; The slewing bearing vibration acquisition subunit includes: The sixth vibration acquisition sensor 11 is used to acquire the vibration of the slewing bearing; The vibration acquisition subunit for the land-sea side portal legs includes: Seventh vibration acquisition sensor 12: used to acquire vibration data of the first gate leg on the sea side; Eighth vibration acquisition sensor 13: used to acquire vibration data of the second gate leg on the sea side; Ninth vibration acquisition sensor 14: used to acquire vibration data of the first gate leg on the landside; Tenth vibration acquisition sensor 15: used to acquire vibration data of the second landside gate leg; The vibration acquisition subunit for the land-sea side trolley includes: Eleventh vibration acquisition sensor 16: used to acquire the vibration of the first vehicle on the sea side; The twelfth vibration acquisition sensor 17 is used to acquire the vibration of the second vehicle on the sea side; The thirteenth vibration acquisition sensor 18 is used to acquire the vibration of the first vehicle on the landside. Fourteenth vibration acquisition sensor 19: used to acquire vibration data of the second vehicle on the landside; The reducer vibration acquisition subunit includes: The fifteenth vibration acquisition sensor 20 is used to acquire the vibration of the reducer of the amplitude transformer mechanism; The sixteenth vibration acquisition sensor 21 is used to acquire the vibration of the reducer of the hoisting mechanism.

[0031] The first vibration acquisition sensor 6 to the sixteenth vibration acquisition sensor 21 are respectively installed at key structural parts such as the elephant trunk bridge hinge point, slewing bearing, sea-land side door leg, sea-land side trolley, luffing mechanism reducer in machine room, and hoisting mechanism reducer. The first vibration acquisition sensor 6 to the sixteenth vibration acquisition sensor 21 are accelerometers that output 4-20mA signals. The vibration monitoring sensors installed on the key structural parts of the gantry crane transmit the monitoring data to the data acquisition unit in the form of hard wiring. The data acquisition unit is equipped with 16 AI signal receiving channels. After receiving the vibration monitoring sensor data, it transmits it to the vibration monitoring server 4 in the form of Profinet protocol. The vibration monitoring server 4 performs calculations based on the received vibration monitoring sensor data to obtain the real-time vibration level of each key structural part during the operation of the gantry crane, and transmits this result to the PLC control unit 2 in the form of Profinet protocol.

[0032] like Figure 5 As shown, the slewing windproof adaptive control unit includes: Wind monitoring unit 36: Used to detect real-time wind speed and direction data of the bulk cargo terminal operating environment; Absolute encoder module 39: Used to detect the real-time angle of the rotary mechanism; Self-locking control unit 40: used for self-locking anchoring of the slewing structure of a pedestal crane; The self-locking control unit 40 includes: N keyholes: evenly distributed around the rotating structure; N≥36.

[0033] Electric anchoring device 35: adopts the form of a telescopic electro-hydraulic actuator; When the electric anchoring device 35 is in the anchoring state, the telescopic electro-hydraulic push rod is engaged with the lock hole. When the electric anchoring device 35 is in the anchoring state, the telescopic electro-hydraulic push rod is separated from the lock hole.

[0034] First limit switch: used to detect whether the electric anchoring device 35 is in the anchoring state; Second limit switch: used to detect when the electric anchoring device 35 is in the released state.

[0035] The slewing windproof adaptive control unit also includes a power supply unit, which provides power to the PLC control unit 2, drive unit 2, absolute encoder module 39, self-locking control unit 40 and wind monitoring unit 36.

[0036] The power supply unit adopts a UPS power supply device 33; Figure 6 It is a UPS power supply device; The UPS power supply device 33 has a power output of 10kVA and a battery life of 24h. It provides emergency power to the PLC module 22, switch 23, DI module, and DO module in the PLC control unit 2, the rotary inverter and absolute encoder in the drive unit 2, and the wind speed and wind direction detection sensor in the rotary windproof adaptive control unit, using hard wiring. After receiving the control command from the DO module in the PLC control unit 2, the contactor 34 (first limit switch and second limit switch) for electric anchoring control in the electric anchoring device 35 performs corresponding engagement and release actions, thereby driving the electro-hydraulic push rod of the electric anchoring device 35 to extend and retract in the form of hard wiring, so as to realize the anchoring and release functions of the electric anchoring device 35. The electric anchoring device 35 electro-hydraulic actuator is equipped with extension and retraction position detection limit switches. When the extension position detection limit switch is activated, it means that the electric anchoring device 35 is in the anchoring state. When the retraction position detection limit switch is activated, it means that the electric anchoring device 35 is in the release state. The anchoring and release signals detected by the limit switches are transmitted to the DI module in the PLC control unit 2 in the form of hard wiring. The wind monitoring unit 36 ​​includes a wind speed monitoring sensor for detecting real-time wind speed data in the bulk cargo terminal operating environment; Wind direction monitoring sensor: used to detect real-time wind direction data in the operating environment of bulk cargo terminals; Wind speed and wind direction sensors are installed on the top of the machine room; The wind speed and wind direction sensors transmit wind speed and wind direction data to the PLC control unit 2 using the Profinet protocol.

[0037] like Figure 7 As shown, drive unit 2 is used to control the movement of the luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of the gantry crane; The drive unit 2 includes a variable amplitude mechanism motor 28: used to provide power to the variable amplitude mechanism; Hoisting mechanism motor 29: Used to provide power to the hoisting mechanism; Rotary mechanism motor 30: used to provide power to the rotating structure; Trolley mechanism motor 31: Used to provide power to the trolley structure; The luffing mechanism motor 28 and the hoisting mechanism motor 29 are installed in the machine room; the slewing mechanism motor 30 is installed on the slewing structure; and the trolley mechanism motor 31 is installed on the trolley structure. The frequency converter 24 of the luffing mechanism is used to drive the motor 28 of the luffing mechanism to rotate in the forward and reverse directions by receiving control commands from the PLC control unit 2, thereby realizing the lifting and lowering actions of the luffing mechanism. Hoisting mechanism frequency converter 25: used to drive the hoisting mechanism motor 29 to rotate in the forward and reverse directions by receiving control commands from the PLC control unit 2, thereby realizing the lifting and lowering actions of the hoisting mechanism; Rotary mechanism frequency converter 26: used to drive the rotary mechanism motor 30 to rotate in the forward and reverse directions by receiving control commands from the PLC control unit 2, thereby realizing the clockwise and counterclockwise operation of the rotary mechanism; Trolley mechanism frequency converter 27: Used to drive trolley mechanism motor 31 to rotate in the forward and reverse directions by receiving control commands from PLC control unit 2, thereby realizing the forward and backward movements of trolley mechanism.

[0038] PLC control unit 2: Used to receive monitoring data on the wire rope winding and unwinding amount, wire rope breakage degree and breakage location of the hoisting mechanism transmitted by wire rope monitoring unit 38, generate the first control signal of the hoisting mechanism, and drive the action of the hoisting mechanism through drive unit 2. The system is used to receive the abnormal vibration level of key parts of the gantry crane structure transmitted by the vibration monitoring unit 1. When a second control signal is generated to suppress or eliminate the abnormal vibration of key parts of the gantry crane structure, the system controls the movement of the luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of the gantry crane through the drive unit 2. Based on the real-time wind direction angle of the bulk cargo terminal operation environment transmitted by the wind monitoring unit 36 ​​and the real-time angle of the slewing mechanism transmitted by the absolute encoder module 39, a third control signal is generated based on the real-time wind speed to control the drive unit 2 and the self-locking control unit 40, thereby realizing adaptive control of the slewing structure of the pedestal crane.

[0039] like Figure 4 As shown, the frequency converter 24 of the luffing mechanism receives control commands from the PLC control unit 2 and drives the motor 28 of the luffing mechanism to rotate in the forward and reverse directions in a hard-wired manner, thereby realizing the rising and falling actions of the luffing mechanism. The hoisting mechanism frequency converter 25 receives control commands from the PLC control unit 2 and drives the hoisting mechanism motor 29 to rotate in the forward and reverse directions in a hard-wired manner, thereby realizing the lifting and lowering actions of the hoisting mechanism. After receiving the drive control command from the PLC control unit 2, the slewing mechanism frequency converter 26 drives the slewing motor to rotate clockwise and counterclockwise in a hard-wired manner, thereby realizing adaptive control of the slewing angle of the slewing structure and slewing damping control during the adaptive adjustment process.

[0040] The absolute encoder transmits the detection signal to the PLC control unit 2 in the form of Profinet protocol; the trolley mechanism frequency converter 27 receives the control command of the PLC control unit 2 and drives the trolley mechanism motor 31 to rotate in the forward and reverse directions in the form of hard wiring, thereby realizing the forward and backward movement of the trolley mechanism.

[0041] PLC control unit 2 includes PLC module 22, switch 23, DI module and DO module, such as Figure 8As shown, the PLC module 22 transmits control commands via the switch 23 to the frequency converters 24 of the luffing mechanism, 25 of the hoisting mechanism, 26 of the slewing mechanism, and 27 of the trolley mechanism in the drive unit 2 using the Profinet protocol. PLC module 22 receives monitoring results from the wire rope monitoring server in the condition monitoring unit via switch 23 using the TCP / IP protocol; PLC module 22 also receives monitoring results from the vibration monitoring server 4 in the condition monitoring unit via switch 23 using the Profinet protocol. PLC module 22 receives data from the absolute encoder and data from the wind speed and wind direction sensors in the slewing windproof adaptive control unit via switch 23 in the form of Profinet protocol. Switch 23 supports Profinet protocol and TCP / IP protocol for data transmission between PLC control unit 2 and drive unit 2, slewing windproof adaptive control unit and wire rope monitoring unit 38; The DI module receives the anchoring and release detection signals of the electric anchoring lock in the slewing windproof adaptive control unit via hard wiring; The DO module uses hard-wired connections to control the engagement and disengagement of the contactor used for electric anchoring control in the slewing windproof adaptive control unit.

[0042] Determining the degree and location of wire breakage in a steel wire rope using magnetic flux detection or machine vision recognition methods includes determining the degree of wire breakage based on magnetic flux detection, calculating the location of wire breakage based on magnetic flux detection, determining the degree of wire breakage based on machine vision recognition, and calculating the location of wire breakage based on machine vision recognition. The process of determining the degree of wire breakage in a steel wire rope based on magnetic flux detection is as follows: When 90%≤K 实际 / K 标准 When the percentage is less than 95%, it is determined that there is a minor breakage in the wire rope at this point. When K 实际 / K 标准 If the percentage is ≤90%, the wire rope is considered to have severe broken wires. Where: K 实际 The magnetic flux of the hoisting wire rope is monitored by the magnetic flux monitoring sensor 37, which is the current magnetic flux of the wire rope passing the sensor. K standard is the standard magnetic flux of a brand new wire rope without broken wires or damage.

[0043] The process of calculating the location of the broken wire in the steel wire rope based on the magnetic flux detection method is as follows: When minor or severe wire rope breakage is detected, the location of the broken wire rope is calculated from the point where the wire rope connects to the lifting device at the top: S1=HH 吊具 +L+S 当前 -S 初始 ; Where: H is the position value of the lifting direction of the lifting device, H 吊具 The height of the lifting device is L, where L is the length of the wire rope from the top pulley of the elephant trunk beam to the 37 magnetic flux monitoring sensors at the rope outlet in the machine room, and S is the height of the lifting device itself. 当前 S represents the current release of the hoisting wire rope detected by the hoisting absolute encoder. 初始 This is the amount of hoisting wire rope released by the absolute value encoder when the lifting device is in the upper stop position.

[0044] The process of determining the degree of wire breakage in a steel wire rope based on machine vision recognition method is as follows: When 110% > P 实际 / (0.5 (P 上 +P 下 When the breakage rate is ≥105%, it is determined that there is a slight breakage in the wire rope at this point. When P 实际 / (0.5 (P 上 +P 下 When the breakage rate is ≥110%, it is determined that the wire rope has suffered severe wire breakage at this point. Where: P 实际 P represents the pixel value in the width direction of the wire rope of the lifting mechanism at each monitoring position from the top of the elephant trunk bridge to the lifting device. 上 The pixel value in the width direction of the steel wire rope is located 10cm above the current monitoring position, and is P. 下 Pixel value in the width direction of the steel wire rope 10cm below the current monitoring position; The method for calculating the location of broken wires in a steel wire rope based on machine vision recognition: When minor or severe wire rope breakage is detected, the location of the broken wire rope is calculated from the point where the wire rope connects to the lifting device at the top: S2=(S 当前 -L) PH 断 / PH 顶 ; Wherein: S 当前 PH represents the current release of the hoisting wire rope detected by the absolute value encoder, where L is the length of the wire rope from the top pulley of the elephant trunk beam to the rope outlet in the machine room at 37 locations, and PH is the current release of the hoisting wire rope. 断 PH represents the pixel value from the location of the broken wire in the wire rope to the top of the lifting device. 顶 The pixel value is the distance from the top pulley of the elephant trunk beam to the top of the lifting device.

[0045] The process for processing the vibration signals of key structural parts transmitted by the data acquisition device to determine whether there is abnormal vibration in the key structural parts of the gantry crane is as follows: When the trolley mechanism of the gantry crane moves, the same abnormal vibration judgment method is used to monitor the seventh vibration acquisition sensor 12 to the fourteenth vibration acquisition sensor 19 in real time. The specific judgment process is as follows: If 1.1 K 标准a >K 实际a ≥1.05 K 标准a The vibration monitoring sensor determines that the abnormal vibration of the corresponding key structural part has reached the alarm level. If K 实际a ≥1.1 K 标准a The vibration monitoring sensor determines that the abnormal vibration of the corresponding key structural part has reached the level of a fault.

[0046] Where: K 实际a The vibration amplitude value is the real-time monitoring value of any one of the seventh vibration acquisition sensors 12 to the fourteenth vibration acquisition sensors 19. K standard a represents the vibration amplitude value of any one of the seventh vibration acquisition sensors 12 to the fourteenth vibration acquisition sensors 19 during normal operation.

[0047] When the luffing mechanism of the gantry crane operates, the same anomaly detection method is used for the data from the first vibration acquisition sensor 6 to the fifth vibration acquisition sensor 10 and the fifteenth vibration acquisition sensor 20. The specific detection process is as follows: If 1.1 K 标准b >K 实际b ≥1.05 K 标准b The vibration monitoring sensor determines that the abnormal vibration of the corresponding key structural part has reached the alarm level. If K 实际b ≥1.1 K 标准b The vibration monitoring sensor determines that the abnormal vibration of the corresponding key structural part has reached the level of a fault.

[0048] Where: K 实际b K represents the vibration amplitude value monitored in real time by any one of the following vibration acquisition sensors: the first vibration acquisition sensor 6 to the fifth vibration acquisition sensor 10 and the fifteenth vibration acquisition sensor 20; 标准b The vibration amplitude value of any one of the vibration acquisition sensors 6 to 10 and 20 during normal operation; When the hoisting mechanism of the gantry crane operates, the data from the first vibration acquisition sensor 6 to the fifth vibration acquisition sensor 10 and the sixteenth vibration acquisition sensor 21 are monitored in real time. The specific judgment process is as follows: If 1.1 K 标准c >K 实际c ≥1.05 K 标准c The system determines that any one of the vibration acquisition sensors, from the first vibration acquisition sensor 6 to the fifth vibration acquisition sensor 10 and the fifteenth vibration acquisition sensor 20, has reached the alarm level for the corresponding key structural part. If K 实际c ≥1.1 K standard c, determines that the abnormal vibration of the corresponding key structural part monitored by any one of the vibration acquisition sensors 6 to 10 and 20 has reached the fault level. Where: K 实际c K represents the vibration amplitude value monitored in real time by any one of the following vibration acquisition sensors: the first vibration acquisition sensor 6 to the fifth vibration acquisition sensor 10 and the fifteenth vibration acquisition sensor 20; 标准c The vibration amplitude value of any one of the vibration acquisition sensors 6 to 10 and 20 during normal operation; When the slewing mechanism of the gantry crane is in motion, the sixth vibration acquisition sensor 11 is monitored in real time. The specific judgment process is as follows: If 1.1 K 标准d >K 实际d ≥1.05 K 标准d The abnormal vibration of the corresponding key structural part monitored by the sixth vibration acquisition sensor 11 has reached the alarm level. If K is actually d≥1.1 K standard d determines that the abnormal vibration of the corresponding key structural part monitored by the sixth vibration acquisition sensor 11 has reached the fault level.

[0049] Where: K 实际d The vibration amplitude value is monitored in real time by the sixth vibration acquisition sensor 11; K 标准d This is the vibration amplitude value of the sixth vibration acquisition sensor 11 during normal operation.

[0050] The calibration method for detecting the rotational displacement of a rotary motor using an absolute encoder and then converting it to angle is as follows: 0=a X origin + b; 360=a X circle + b; Where: a is the encoder angle conversion ratio coefficient, b is the encoder angle conversion correction coefficient, X origin is the encoder detection value when the rotary mechanism is at the 0-degree initial position, and X circle is the encoder detection value when the rotary mechanism is at the position of one 360-degree rotation. Solve the above system of equations to obtain the values ​​of encoder angle conversion ratio factor a and encoder angle conversion correction factor b.

[0051] The calculation method for the real-time angle value of the rotary mechanism based on the detection data of the absolute encoder is as follows: Φ=a X+b; Where: X is the real-time detected value of the absolute encoder.

[0052] The encoder detects the rotational displacement of the rotary motor to calculate the corresponding rotation angle. For example, if the rotation angle is 0 degrees, the absolute encoder value is 100. When the rotation angle reaches 90 degrees, the rotary motor needs to rotate 2000 times, and the absolute encoder value becomes 9100. This change in encoder value can be used to calculate the actual rotation angle of the rotary mechanism.

[0053] The process of comparing the real-time wind direction angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit 36 ​​with the real-time angle of the slewing mechanism transmitted by the absolute encoder module 39, and generating a control signal based on the real-time wind speed to control the drive unit 2 and the self-locking control unit 40 to adaptively control the slewing structure of the pedestal crane is as follows: The real-time wind direction angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit 36 ​​is compared with the real-time angle of the slewing mechanism transmitted by the absolute encoder module 39: When the deviation between the minimum windward angle of the upper part of the gantry crane above the slewing structure and the wind direction angle is less than the threshold angle, no adaptive adjustment is required; 15° ≥ the threshold angle ≥ 8°. When the minimum windward angle of the upper part of the gantry crane above the slewing structure deviates from the wind direction angle by ≥ the threshold angle, proceed to the next step; The self-locking control unit 40 releases the electric anchoring device 35; The control drive unit 2 performs adaptive adjustment control of the slewing angle according to the given value of the slewing damping correction until the slewing structure rotates to the adaptive ideal angle. During the adaptive adjustment of the slewing angle, when the slewing structure is subjected to wind force and the slewing angle exceeds the theoretical angle of the adaptive adjustment, the slewing inverter in the control drive unit 2 outputs the reverse damping control torque to prevent the slewing structure from rotating uncontrollably at high speed. The self-locking control unit 40 anchors the electric anchoring device 35.

[0054] The calculation process for the given value of the slewing damping correction is as follows: The specific calculation method for determining the ideal windproof adaptive angle of a gantry crane is as follows: The reference is based on south as 0°, west as 90°, north as 180°, and east as 270°; When (Φ N -Φ 风 )<(Φ N+1 -Φ 风 When the ideal windproof angle Φ of the gantry crane is 0, 理想 For Φ N ; When (Φ N -Φ 风 )≥(Φ N+1 -ω 风 When the ideal windproof angle Φ of the gantry crane is 0, 理想 For Φ N+1 ; Where: Φ 风 Φ is the wind direction angle detected by the wind monitoring unit 36. N Φ is the angle of the nearest keyhole in the counterclockwise direction of the wind direction. N+1 The angle of the nearest keyhole in the clockwise direction of the wind direction; Based on the wind-resistant adaptive ideal angle of the gantry crane, the slewing angular velocity limit value is determined, and the calculation method of the slewing angular velocity limit value ω is as follows: ω=(2 β (Φ-Φ 理想 )) 0.5 ; Where: β is the angular acceleration of the rotary mechanism, Φ is the real-time angle value of the rotary mechanism, Φ 理想 Ideal angle for wind protection and adaptive design of gantry cranes; The rotational damping is calculated based on the aforementioned rotational angular velocity limit ω, and the rotational damping correction setpoint ω 阻尼 The calculation formula is as follows: ω 阻尼 =((Φ-Φ 理论 ) / (Φ理想 -Φ 起始 )) 0.5 ω Where: ω 阻尼 Φ represents the actual angle of the slewing mechanism. 理论 For the adaptive adjustment of the rotary mechanism, the corresponding theoretical angle, Φ 理想 For the ideal windproof adaptive angle of the gantry crane, Φ 起始 ω represents the initial angle before the adaptive adjustment of the slewing mechanism, and ω represents the angular velocity limit value for the adaptive adjustment of the slewing mechanism.

[0055] This technology enhances the safety and stability of gantry crane operation by equipping the equipment with vibration monitoring and suppression devices, wire rope detection and breakage prevention, and wind-resistant adaptive devices for the slewing mechanism. The steady-state control system of the gantry crane is the core component ensuring the safe and efficient operation of the equipment, guaranteeing the stability of bulk cargo terminal operations and improving their efficiency.

[0056] Example 1: Taking a 40t grab bucket gantry crane as an example, this paper explains the control method of the steady-state control system of the gantry crane.

[0057] The control process of the steady-state control system of the gantry crane is as follows: Figure 9 As shown: S11: The steady-state control system of the gantry crane is activated; S12: In the event of strong winds during non-operational conditions, the windproof adaptive device for the gantry crane's slewing will be activated. S13: When the wind speed is detected to exceed the windproof setting threshold of the slewing structure of the gantry crane, the windproof adaptive adjustment of the slewing mechanism is performed. S14: Repeat S12 to S13 until the unloading operation begins, and the gantry crane's slewing windproof adaptive device function is turned off. S15: Unloading operation begins, and the functions of the gantry crane wire rope online monitoring system and the gantry crane vibration online monitoring system are activated; S16: When a minor or severe wire breakage is detected in the wire rope, an alarm will be triggered to limit the speed or to exit the rope replacement control at the speed limit. S17: When the vibration amplitude value of a key structural part of a gantry crane is detected to reach the alarm or fault level, corresponding vibration suppression control shall be performed. S18: Repeat S15 to S17 until the unloading operation is completed, and turn off the functions of the gantry crane wire rope online monitoring system and the gantry crane vibration online monitoring system. S19: Repeat S12 to S18 to maintain steady-state operation of the gantry crane.

[0058] The main functions of the steady-state control system for gantry cranes—wire rope monitoring and breakage prevention, vibration monitoring and suppression, and wind-resistant adaptive slewing mechanism—are described in detail below: The control process of the online monitoring system for wire ropes of gantry cranes is as follows: Figure 10 As shown: S21: Unloading operation begins, and the online monitoring system for the gantry crane's wire rope is activated. S22: The wire rope magnetic flux monitoring sensor and high-definition camera 32 begin data sampling, and the wire rope broken wire monitoring function based on magnetic flux detection and machine vision recognition technology is activated. S23: When a minor wire breakage occurs, an alarm is triggered, and the hoisting mechanism of the gantry crane operates at a speed limited to 50%. S24: When a severe wire breakage occurs, the system issues a fault, and the gantry crane hoisting mechanism is only allowed to exit the operation at a speed limited to 10% before the wire rope is replaced. S25: Repeat S22 to S24 until the unloading operation is completed, and then turn off the online monitoring system for the gantry crane wire rope.

[0059] The control process of the online vibration monitoring system for gantry cranes is as follows: Figure 11 As shown: S31: Unloading operation begins, and the online vibration monitoring system for the gantry crane is activated. S32: Vibration monitoring sensor begins data sampling, and real-time vibration level judgment function is activated; S33: When the gantry crane's trolley mechanism is in its acceleration / deceleration phase, if the vibration amplitude value monitored in real-time by any of the seventh to fourteenth vibration sensors 19 reaches an alarm or fault level, the PLC control unit 2 will optimize and adjust the acceleration / deceleration values ​​of the trolley mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration and deceleration values ​​a of the trolley mechanism 大车调整 =K a a 大车 ; Where: K a The vibration suppression optimization coefficient for the acceleration and deceleration phases of the trolley mechanism is set to 0.8, a. 大车 These are the acceleration and deceleration values ​​before the adjustment of the trolley mechanism.

[0060] When the gantry crane's trolley mechanism is running at a constant speed, and the vibration amplitude value monitored in real time by any of the seventh to fourteenth vibration sensors 19 reaches an alarm or fault level, the PLC control unit 2 will optimize and adjust the trolley mechanism's running speed to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted trolley mechanism operating speed value V 大车调整 =K A V 大车 The speed value corresponding to the vibration amplitude reaching the alarm or fault level will be added to the given speed shielding zone of the trolley mechanism. In subsequent operation of the trolley mechanism, the speed setpoint in the given shielding zone will be controlled according to the optimized and adjusted operating speed value. The trolley mechanism operates using variable frequency speed control. Different speed outputs of the frequency converter correspond to different frequency values. Different equipment structures may experience resonance at specific frequency outputs, leading to severe equipment vibration. By using detection methods to determine the speed setting and frequency at which resonance occurs, this speed setting is added to a designated shielded zone. During speed regulation, the trolley mechanism avoids resonance by exceeding the speed recorded within this shielded zone.

[0061] Where: K A The vibration suppression optimization coefficient for the trolley mechanism during uniform motion is set to 0.95. 大车 This refers to the operating speed value of the trolley mechanism before adjustment.

[0062] When the luffing mechanism of the gantry crane reaches an alarm or fault level during its acceleration and deceleration phase, if the vibration amplitude value monitored in real time by any of the vibration acquisition sensors 6 through 10 and 20 reaches the level of an alarm, the PLC control unit 2 will optimize and adjust the acceleration and deceleration values ​​of the luffing mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration / deceleration values ​​a of the variable amplitude mechanism 变幅调整 =K b a 变幅 ; Where: K b The vibration suppression optimization coefficient for the acceleration and deceleration phases of the amplitude-changing mechanism is set to 0.8, a. 变幅 These are the acceleration and deceleration values ​​before the amplitude change mechanism is adjusted.

[0063] When the luffing mechanism of the gantry crane is running at a constant speed, if the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (first vibration acquisition sensor 6 to fifth vibration acquisition sensor 10 and fifteenth vibration acquisition sensor 20) reaches the alarm or fault level, the PLC control unit 2 will optimize and adjust the operating speed of the luffing mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted operating speed value V of the luffing mechanism 变幅调整 =K B V 变幅The speed value corresponding to the vibration amplitude reaching the alarm or fault level is added to the speed setpoint shielding zone of the luffing mechanism. In subsequent operation of the luffing mechanism, the speed setpoint in the setpoint shielding zone is controlled according to the optimized and adjusted operating speed value. Where: K B The vibration suppression optimization coefficient for the constant velocity motion phase of the amplitude-changing mechanism is set to 0.95. 变幅 This is the operating speed value of the luffing mechanism before adjustment.

[0064] When the hoisting mechanism of the gantry crane reaches an alarm or fault level during its acceleration and deceleration phase, if the vibration amplitude value monitored in real time by any of the vibration acquisition sensors 6 to 10 and 21 reaches the level of an alarm, the PLC control unit 2 will optimize and adjust the acceleration and deceleration values ​​of the hoisting mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted hoisting mechanism acceleration and deceleration values ​​a 起升调整 =K c a 起升 ; Its: K c The vibration suppression optimization coefficient for the hoisting mechanism during acceleration and deceleration is set to 0.8, a. 起升 These are the acceleration and deceleration values ​​before the hoisting mechanism is adjusted.

[0065] When the hoisting mechanism of the gantry crane is running at a constant speed, if the vibration amplitude value monitored in real time by any of the vibration acquisition sensors 6 to 10 and 21 reaches the alarm or fault level, the PLC control unit 2 will optimize and adjust the hoisting mechanism's operating speed to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted hoisting mechanism operating speed value V 起升调整 =K C V 起升 The speed value corresponding to the vibration amplitude reaching the alarm or fault level will be added to the hoisting mechanism's operating speed setpoint shielding zone. Subsequently, when the hoisting mechanism is running, the speed setpoint in the setpoint shielding zone will be controlled according to the optimized and adjusted operating speed value. Where K C The vibration suppression optimization coefficient for the hoisting mechanism during uniform motion is set to 0.95. 起升 This is the operating speed value of the hoisting mechanism before adjustment.

[0066] When the slewing mechanism of the gantry crane reaches an alarm or fault level as monitored in real time by the sixth vibration acquisition sensor 11 during its acceleration and deceleration phase, the PLC control unit 2 will optimize and adjust the acceleration and deceleration values ​​of the slewing mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration / deceleration values ​​a of the slewing mechanism 回转调整 =K d a 回转 ; Where: K d The vibration suppression optimization coefficient for the acceleration and deceleration phases of the rotary mechanism is set to 0.8, a. 回转 These are the acceleration and deceleration values ​​before the adjustment of the slewing mechanism.

[0067] When the slewing mechanism of the gantry crane reaches an alarm or fault level as monitored in real time by the sixth vibration acquisition sensor 11 during its uniform speed operation, the PLC control unit 2 will optimize and adjust the slewing mechanism's operating speed to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted operating speed value V of the slewing mechanism 回转调整 =K D V 回转 The speed value corresponding to the vibration amplitude reaching the alarm or fault level is added to the speed setpoint shielding zone of the slewing mechanism. In subsequent operation of the slewing mechanism, the speed setpoint in the setpoint shielding zone is controlled according to the optimized and adjusted operating speed value. Where K D The vibration suppression optimization coefficient for the uniform motion phase of the rotary mechanism is set to 0.95, V. 回转 This is the operating speed value of the slewing mechanism before adjustment.

[0068] S34: Repeat S33 to step ten until the unloading operation is completed, and then turn off the online vibration monitoring system for the gantry crane.

[0069] The control process of the slewing windproof adaptive device for gantry cranes is as follows: Figure 12 As shown: S41: In the event of strong winds during non-operational conditions, the windproof adaptive device for the gantry crane's slewing will be activated. S42: PLC control unit 2 begins to receive wind speed and wind direction detection data from wind monitoring unit 36 ​​in real time; S43: When the wind speed is detected to exceed the wind protection threshold of the slewing structure of the gantry crane, the adaptive adjustment function of the slewing method is activated. S44: PLC control unit 2 compares the wind direction angle and the angle of the slewing structure. If the minimum windward angle of the upper part of the gantry crane above the slewing structure deviates from the wind direction angle by less than 10°, it is at the optimal windward angle and no adaptive adjustment is required. If the minimum windward angle of the upper part of the gantry crane above the slewing structure deviates from the wind direction angle by more than or equal to 10°, adaptive adjustment is required. S45: PLC control unit 2 controls self-locking control unit 40 to release electric anchoring device 35; S46: PLC control unit 2 controls drive unit 2 to perform adaptive adjustment control of rotation angle; S47: During the adaptive adjustment of the slewing angle, the PLC control unit 2 detects the angle of the slewing mechanism in real time. Once the slewing structure is affected by wind and the slewing angle exceeds the theoretical angle of the adaptive adjustment, the PLC control unit 2 controls the slewing inverter in the drive unit 2 to output the reverse damping control torque to prevent the slewing structure from rotating uncontrollably at high speed. S48: Continue adaptive adjustment control of the slewing angle until the slewing structure reaches the adaptive ideal angle; S49: PLC control unit 2 controls self-locking control unit 40 to anchor electric anchoring device 35; S410: Repeat S42 to S49 until the windy weather ends, and the gantry crane's slewing windproof adaptive device function is turned off.

[0070] 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; and these 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.

Claims

1. A steady-state control system for a gantry crane, characterized in that: include Wire rope monitoring unit: used to monitor the amount of wire rope winding and unwinding in the hoisting mechanism, as well as the degree and location of wire rope breakage. Vibration monitoring unit: used to collect vibration signals from key structural parts of the gantry crane, process them, and determine whether there is abnormal vibration in the key structural parts of the gantry crane; Wind monitoring unit: Used to detect real-time wind speed and direction data in the operating environment of bulk cargo terminals; Absolute encoder module: used to detect the real-time angle of the rotary mechanism; Self-locking control unit: used for self-locking anchoring of the slewing structure of a pedestal crane; Drive unit: Used to control the movement of the luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of gantry crane; PLC control unit: Used to receive monitoring data transmitted by the wire rope monitoring unit on the wire rope winding and unwinding amount, wire rope breakage degree and breakage location of the hoisting mechanism, generate the first control signal of the hoisting mechanism, and drive the hoisting mechanism to move through the drive unit; Used to receive the abnormal vibration level of key parts of the gantry crane structure transmitted by the vibration monitoring unit, and when a second control signal is generated to suppress or eliminate the abnormal vibration of key parts of the gantry crane structure, the drive unit controls the movement of the luffing mechanism, hoisting mechanism, slewing mechanism or trolley mechanism of the gantry crane. Based on the real-time wind direction and angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit, the real-time angle of the slewing mechanism transmitted by the absolute encoder module, and the real-time wind speed, a third control signal is generated to control the drive unit and the self-locking control unit, thereby realizing adaptive control of the slewing structure of the pedestal crane.

2. The steady-state control system for a gantry crane according to claim 1, characterized in that: The wire rope monitoring unit includes: Lifting absolute encoder: used to monitor the amount of wire rope wound up and down on the hoisting mechanism drum; Magnetic flux monitoring sensor for hoisting wire rope: used to collect the magnetic flux value of the hoisting wire rope at the rope outlet in the machine room; High-definition camera: used to capture image data of the hoisting mechanism wire rope between the top of the elephant trunk and the lifting device; Monitoring data exchange: used to receive and transmit the winding and unwinding amount of the hoisting mechanism drum wire rope transmitted by the hoisting absolute encoder, the magnetic flux value of the hoisting wire rope passing through the rope outlet of the machine room transmitted by the hoisting wire rope magnetic flux monitoring sensor, and the image data of the hoisting mechanism wire rope from the top of the elephant trunk to the lifting device transmitted by the high-definition camera. Wire rope monitoring server: Used to receive the winding and unwinding amount of the hoisting mechanism drum wire rope, the magnetic flux value of the hoisting wire rope passing through the rope outlet of the machine room, and the image data of the hoisting mechanism wire rope from the top of the elephant trunk beam to the lifting device transmitted by the monitoring data exchange. It uses magnetic flux detection method or machine vision recognition method to determine the degree of wire breakage and calculate the location of wire breakage.

3. The steady-state control system for a gantry crane according to claim 2, characterized in that: The process of determining the degree of wire breakage in a steel wire rope using magnetic flux detection or machine vision recognition methods includes determining the degree of wire breakage based on magnetic flux detection, as detailed below: When 90%≤K 实际 / K 标准 When the percentage is less than 95%, it is determined that there is a minor breakage in the wire rope at this point. When K 实际 / K 标准 If the percentage is ≤90%, the wire rope is considered to have severe broken wires. Where: K 实际 K represents the magnetic flux of the wire rope passing the sensor. 标准 The standard magnetic flux of a brand new steel wire rope with no broken wires or damage; The process of determining the degree of wire breakage in a steel wire rope using magnetic flux detection or machine vision recognition methods also includes determining the degree of wire breakage based on machine vision recognition methods, as detailed below: When 110% > P 实际 / (0.5 (P 上 +P 下 When the breakage rate is ≥105%, it is determined that there is a slight breakage in the wire rope at this point. When P 实际 / (0.5 (P 上 +P 下 When the breakage rate is ≥110%, it is determined that the wire rope has suffered severe wire breakage at this point. Where: P 实际 P represents the pixel value in the width direction of the wire rope of the lifting mechanism at each monitoring position from the top of the elephant trunk bridge to the lifting device. 上 The pixel value in the width direction of the steel wire rope at a position N cm above the current monitoring location is P. 下 The pixel value in the width direction of the steel wire rope at a current monitoring position N cm downwards.

4. The steady-state control system for a gantry crane according to claim 2, characterized in that: The process of determining the location of the broken wire in the wire rope using magnetic flux detection or machine vision recognition methods includes calculating the location of the broken wire based on the magnetic flux detection method, as detailed below: When a minor or severe wire rope breakage is detected, the location of the broken wire rope is calculated starting from the connection point between the wire rope and the lifting device at the top. The specific formula is as follows: S1=H-H 吊具 +L+S 当前 -S 初始 ; Where: H is the height position value of the lifting device in the lifting direction, H 吊具 The height of the lifting device is L, where L is the length of the wire rope from the top pulley of the elephant trunk beam to the magnetic flux monitoring sensor at the rope outlet in the machine room, and S is the height of the lifting device itself. 当前 S represents the current release of the hoisting wire rope detected by the hoisting absolute encoder. 初始 The amount of hoisting wire rope released is detected by the hoisting absolute encoder when the spreader is in the upper stop position; The process of determining the location of the broken wire in the wire rope using magnetic flux detection or machine vision recognition methods includes the following process of calculating the location of the broken wire based on machine vision recognition methods: When a minor or severe wire rope breakage is detected, the location of the broken wire rope is calculated starting from the connection point between the wire rope and the lifting device at the top. The specific formula is as follows: S2=(S 当前 -L) PH 断 / PH 顶 ; Wherein: S 当前 PH represents the current release of the hoisting wire rope detected by the hoisting absolute encoder, where L is the length of the wire rope from the top pulley of the elephant trunk beam to the magnetic flux monitoring sensor at the rope outlet in the machine room. 断 PH represents the pixel value from the location of the broken wire in the wire rope to the top of the lifting device. 顶 The pixel value is the distance from the top pulley of the elephant trunk beam to the top of the lifting device.

5. A steady-state control system for a gantry crane according to claim 2, characterized in that: The process of receiving the first control signal of the hoisting mechanism transmitted by the PLC control unit and driving the operation of the hoisting mechanism is as follows: When a minor wire breakage occurs, an alarm signal is issued, and the hoisting mechanism of the gantry crane is controlled to operate at a speed limited to 50%. When a severe wire breakage occurs, a fault signal is issued, and the hoisting mechanism of the gantry crane is only allowed to exit the operation at a speed limited to 10% before the wire rope is replaced.

6. A steady-state control system for a gantry crane according to claim 2, characterized in that: The vibration acquisition unit includes an elephant trunk bridge vibration acquisition subunit, a slewing bearing vibration acquisition subunit, and a sea-land side door leg vibration acquisition subunit. The elephant trunk bridge vibration acquisition subunit includes: The first vibration acquisition sensor is used to acquire vibrations at the pivot point at the root of the object's nose. The second vibration acquisition sensor is used to acquire the vibration of the No. 1 hinge point at the root of the object's nose. The third vibration acquisition sensor is used to acquire the vibration of the No. 2 hinge point at the root of the object's nose. The fourth vibration acquisition sensor is used to acquire vibration data at the #3 pivot point at the root of the object's nose. The fifth vibration acquisition sensor is used to acquire the vibration of the top pulley on the bridge of the nose of the object; The slewing bearing vibration acquisition subunit includes: The sixth vibration acquisition sensor: used to acquire the vibration of the slewing bearing; The vibration acquisition subunit for the land-sea side portal legs includes: The seventh vibration acquisition sensor is used to acquire vibration data of the first gate leg on the sea side. The eighth vibration acquisition sensor is used to acquire vibration data of the second leg on the sea side. Ninth vibration acquisition sensor: used to acquire vibration data of the first landside gate leg; The tenth vibration acquisition sensor: used to acquire vibration data of the second landside gate leg; The vibration acquisition subunit for the land-sea side trolley includes: The eleventh vibration acquisition sensor: used to acquire the vibration of the first vehicle on the sea side; The twelfth vibration acquisition sensor: used to acquire the vibration of the second vehicle on the sea side; The thirteenth vibration acquisition sensor: used to acquire the vibration of the first vehicle on the landside; The fourteenth vibration acquisition sensor: used to acquire the vibration of the second vehicle on the landside; The reducer vibration acquisition subunit includes: The fifteenth vibration acquisition sensor: used to acquire the vibration of the reducer of the amplitude transformer mechanism; The sixteenth vibration acquisition sensor is used to acquire vibration data from the reducer of the hoisting mechanism.

7. The steady-state control system for a gantry crane according to claim 1, characterized in that: The process of receiving the abnormal vibration level of key parts of the gantry crane structure transmitted by the vibration monitoring unit and generating a second control signal to suppress or eliminate the abnormal vibration of key parts of the gantry crane structure is as follows: When the trolley mechanism of the gantry crane moves, the same abnormal vibration judgment method is used for the seventh to fourteenth vibration acquisition sensors, as follows: If 1.1 K 标准a >K 实际a ≥1.05 K 标准a The vibration acquisition sensor is used to determine whether the abnormal vibration of the corresponding key structural part has reached the alarm level. If K 实际a ≥1.1 K 标准a The abnormal vibration of the corresponding key structural parts monitored by the vibration acquisition sensor is determined to have reached the level of a fault. Where K 实际a K represents the vibration amplitude value monitored in real time by any one of the seventh to fourteenth vibration acquisition sensors; 标准a The vibration amplitude value of any one of the seventh to fourteenth vibration sensors during normal operation; When the luffing mechanism of the gantry crane is activated, the same anomaly detection method is used for the data from the first vibration acquisition sensor to the fifth vibration acquisition sensor and the fifteenth vibration acquisition sensor. If 1.1 K 标准b >K 实际b ≥1.05 K 标准b The vibration acquisition sensor is used to determine whether the abnormal vibration of the corresponding key structural part has reached the alarm level. If K 实际b ≥1.1 K 标准b The abnormal vibration of the corresponding key structural parts monitored by the vibration acquisition sensor is determined to have reached the level of a fault. Where K 实际b K represents the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (first to fifth and fifteenth vibration acquisition sensors); 标准b The vibration amplitude value of any one of the vibration acquisition sensors, from the first to the fifth and the fifteenth vibration acquisition sensors, during normal operation; When the hoisting mechanism of the gantry crane operates, the data from the first to the fifth vibration acquisition sensors and the sixteenth vibration acquisition sensor are monitored in real time. If 1.1 K 标准c >K 实际c ≥1.05 K 标准c The system determines that any one of the vibration acquisition sensors (first to fifth and fifteenth) has detected abnormal vibrations in the corresponding key structural parts, which has reached the alarm level. If K 实际c ≥1.1 K 标准c The abnormal vibration of the corresponding key structural part monitored by any one of the vibration acquisition sensors (first to fifth and fifteenth) reaches the level of a fault. Where: K 实际c K represents the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (first to fifth and fifteenth vibration acquisition sensors); 标准c The vibration amplitude value of any one of the vibration acquisition sensors, from the first to the fifth and the fifteenth vibration acquisition sensors, during normal operation; When the slewing mechanism of the gantry crane operates, the sixth vibration acquisition sensor is monitored in real time. If 1.1 K 标准d >K 实际d ≥1.05 K 标准d The system determines that the abnormal vibration of the corresponding key structural part monitored by the sixth vibration acquisition sensor has reached the alarm level. If K 实际d ≥1.1 K 标准d The abnormal vibration of the corresponding key structural part monitored by the sixth vibration acquisition sensor is determined to have reached the level of a fault. Where K 实际d K represents the vibration amplitude value monitored in real time by the sixth vibration acquisition sensor. 标准d This represents the vibration amplitude value when the sixth vibration acquisition sensor is operating normally.

8. The steady-state control system for a gantry crane according to claim 1, characterized in that: The process of receiving the abnormal vibration level of key parts of the gantry crane structure transmitted by the vibration monitoring unit and generating a control signal to suppress or eliminate the abnormal vibration of key parts of the gantry crane structure is as follows: When the gantry crane's trolley mechanism reaches an alarm or fault level during its acceleration and deceleration phases, if the vibration amplitude value monitored in real-time by any of the seven to fourteenth vibration sensors reaches the alarm or fault level, the acceleration and deceleration values ​​of the trolley mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration and deceleration values ​​a of the trolley mechanism 大车调整 =K a a 大车 ; Where: K a The vibration suppression optimization coefficient for the acceleration and deceleration phases of the trolley mechanism is set to 0.8, a. 大车 These are the acceleration and deceleration values ​​before the adjustment of the trolley mechanism; When the gantry crane's trolley mechanism is running at a constant speed, and the vibration amplitude value monitored in real time by any one of the vibration acquisition sensors (seventh to fourteenth vibration acquisition sensors) reaches the alarm or fault level, the trolley mechanism's running speed will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted trolley mechanism operating speed value V 大车调整 =K A V 大车 The speed value corresponding to the vibration amplitude reaching the alarm or fault level will be added to the given speed shielding zone of the trolley mechanism. In subsequent operation of the trolley mechanism, the speed setpoint in the given shielding zone will be controlled according to the optimized and adjusted operating speed value. Where: K A The vibration suppression optimization coefficient for the trolley mechanism during uniform motion is set to 0.

95. 大车 This refers to the operating speed value of the trolley mechanism before adjustment. When the luffing mechanism of a gantry crane reaches an alarm or fault level in real-time monitoring by any one of the first to fifth vibration sensors or the fifteenth vibration sensor during its acceleration and deceleration phases, the acceleration and deceleration values ​​of the luffing mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration / deceleration values ​​a of the variable amplitude mechanism 变幅调整 =K b a 变幅 ; Where: K b The vibration suppression optimization coefficient for the acceleration and deceleration phases of the amplitude-changing mechanism is set to 0.8, a. 变幅 These are the acceleration and deceleration values ​​of the luffing mechanism before adjustment. When the luffing mechanism of a gantry crane reaches an alarm or fault level during its uniform speed operation phase, if the vibration amplitude value monitored in real time by any one of the first to fifth vibration sensors or the fifteenth vibration sensor reaches the level required for an alarm, the operating speed of the luffing mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted operating speed value V of the luffing mechanism 变幅调整 =K B V 变幅 The speed value corresponding to the vibration amplitude reaching the alarm or fault level is added to the speed setpoint shielding zone of the luffing mechanism. In subsequent operation of the luffing mechanism, the speed setpoint in the setpoint shielding zone is controlled according to the optimized and adjusted operating speed value. Where: K B The vibration suppression optimization coefficient for the constant velocity motion phase of the amplitude-changing mechanism is set to 0.

95. 变幅 This is the operating speed value of the luffing mechanism before adjustment. When the hoisting mechanism of a gantry crane reaches an alarm or fault level during its acceleration and deceleration phase, if the vibration amplitude value monitored in real time by any one of the first to fifth vibration sensors or the sixteenth vibration sensor reaches the alarm or fault level, the PLC control unit will optimize and adjust the acceleration and deceleration values ​​of the hoisting mechanism to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted hoisting mechanism acceleration and deceleration values ​​a 起升调整 =K c a 起升 ; Where K c The vibration suppression optimization coefficient for the hoisting mechanism during acceleration and deceleration is set to 0.8, a. 起升 These are the acceleration and deceleration values ​​before the hoisting mechanism is adjusted. Step 8: When the hoisting mechanism of the gantry crane reaches an alarm or fault level during its uniform speed operation phase, if any one of the vibration acquisition sensors (first to fifth and sixteenth vibration acquisition sensors) detects a vibration amplitude that triggers an alarm, the hoisting mechanism's operating speed will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted hoisting mechanism operating speed value V 起升调整 =K C V 起升 The speed value corresponding to the vibration amplitude reaching the alarm or fault level will be added to the hoisting mechanism's operating speed setpoint shielding zone. Subsequently, when the hoisting mechanism is running, the speed setpoint in the setpoint shielding zone will be controlled according to the optimized and adjusted operating speed value. Where K C The vibration suppression optimization coefficient for the hoisting mechanism during uniform motion is set to 0.

95. 起升 This is the operating speed value of the hoisting mechanism before adjustment. When the slewing mechanism of a gantry crane reaches an alarm or fault level as monitored in real time by the sixth vibration acquisition sensor during its acceleration and deceleration phase, the acceleration and deceleration values ​​of the slewing mechanism will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted acceleration / deceleration values ​​a of the slewing mechanism 回转调整 =K d a 回转 ; Where K d The vibration suppression optimization coefficient for the acceleration and deceleration phases of the rotary mechanism is set to 0.8, a. 回转 These are the acceleration and deceleration values ​​before the adjustment of the slewing mechanism. When the slewing mechanism of the gantry crane reaches an alarm or fault level as monitored in real time by the sixth vibration acquisition sensor during its uniform speed operation, the slewing mechanism's operating speed will be optimized and adjusted to suppress vibration. The specific optimization and adjustment method is as follows: Optimized and adjusted operating speed value V of the slewing mechanism 回转调整 =K D V 回转 The speed value corresponding to the vibration amplitude reaching the alarm or fault level is added to the speed setpoint shielding zone of the slewing mechanism. In subsequent operation of the slewing mechanism, the speed setpoint in the setpoint shielding zone is controlled according to the optimized and adjusted operating speed value. Where: K D The vibration suppression optimization coefficient for the uniform motion phase of the rotary mechanism is set to 0.95, V. 回转 This is the operating speed value of the slewing mechanism before adjustment.

9. A steady-state control system for a gantry crane according to claim 1, characterized in that: The process of comparing the real-time wind direction and angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit, the real-time angle of the slewing mechanism transmitted by the absolute encoder module, and the real-time wind speed to generate a third control signal, and controlling the third drive unit and the self-locking control unit to adaptively control the slewing structure of the pedestal crane is as follows: The real-time wind direction angle of the bulk cargo terminal operating environment transmitted by the wind monitoring unit is compared with the real-time angle of the slewing mechanism transmitted by the absolute encoder module: When the deviation between the minimum windward angle of the upper part of the gantry crane above the slewing structure and the wind direction angle is less than the threshold angle, no adaptive adjustment is required; When the minimum windward angle of the upper part of the gantry crane above the slewing structure deviates from the wind direction angle by ≥ the threshold angle, proceed to the next step; The self-locking control unit releases the electric anchoring device; The control drive unit performs adaptive adjustment control of the slewing angle according to the given value of the slewing damping correction until the slewing structure rotates to the adaptive ideal angle. During the adaptive adjustment of the slewing angle, when the slewing structure is subjected to wind force and the slewing angle exceeds the theoretical angle of the adaptive adjustment, the slewing inverter in the control drive unit outputs reverse damping control torque to prevent the slewing structure from rotating uncontrollably at high speed. The self-locking control unit anchors the electric anchoring device.

10. A steady-state control system for a gantry crane according to claim 9, characterized in that: The calculation process for the given value of the slewing damping correction is as follows: The specific calculation method for determining the ideal windproof adaptive angle of a gantry crane is as follows: The reference is based on south as 0°, west as 90°, north as 180°, and east as 270°; When (Φ N -Φ 风 )<(Φ N+1 -Φ 风 When the ideal windproof angle Φ of the gantry crane is 0, 理想 For Φ N ; When (Φ N -Φ 风 )≥(Φ N+1 -ω 风 When the ideal windproof angle Φ of the gantry crane is 0, 理想 For Φ N+1 ; Where: Φ 风 Φ is the wind direction angle detected by the wind monitoring unit. N Φ is the angle of the nearest keyhole in the counterclockwise direction of the wind direction. N+1 The angle of the nearest keyhole in the clockwise direction of the wind direction; Based on the wind-resistant adaptive ideal angle of the gantry crane, the slewing angular velocity limit value is determined, and the calculation method of the slewing angular velocity limit value ω is as follows: ω=(2 b (F-F) 理想 )) 0.5 ; Where: β is the angular acceleration of the rotary mechanism, Φ is the real-time angle value of the rotary mechanism, Φ 理想 Ideal angle for wind protection and adaptive design of gantry cranes; The rotational damping is calculated based on the aforementioned rotational angular velocity limit ω, and the rotational damping correction setpoint ω 阻尼 The calculation formula is as follows: oh 阻尼 =((Φ-Φ 理论 ) / (Φ 理想 -F 起始 )) 0.5 oh Where: ω 阻尼 Φ represents the actual angle of the slewing mechanism. 理论 For the adaptive adjustment of the rotary mechanism, the corresponding theoretical angle, Φ 理想 For the ideal windproof adaptive angle of the gantry crane, Φ 起始 ω represents the initial angle before the adaptive adjustment of the slewing mechanism, and ω represents the angular velocity limit value for the adaptive adjustment of the slewing mechanism.

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