A multi-dimensional safety protection method and system for a fixed rotary crane

Abstract

The application provides a fixed rotary crane multi-dimensional safety protection method and system, comprising the following steps: S1, detecting the collision risk of each area in the rotary direction through the millimeter wave radar installed at the end of the boom, the middle part and the rear part of the machine room; detecting the collision risk of the lower surface of the boom through the laser anti-collision device at the lower side of the middle part of the boom; detecting the weight value of the hoisted object through the main hook weighing sensor and the auxiliary hook weighing sensor, determining the rated lifting capacity according to the luffing angle and performing overload judgment; detecting the real-time wind speed through the anemograph and performing gale early warning; collecting vibration data through the vibration monitoring sensor of each key part and determining the vibration state. S2, when any detection item in S1 determines that there is a risk, the corresponding mechanism is terminated to perform dangerous action and an alarm signal is sent. The application constructs a comprehensive active defense system integrating monitoring, early warning and intervention through deep fusion of multi-source sensing technology, intelligent algorithm and real-time control.

Description

Technical Field

[0001] This invention relates to the field of crane safety technology, and more particularly to a multi-dimensional safety protection method and system for a fixed rotary crane. Background Technology

[0002] Safety protection for stationary rotary cranes involves multiple aspects, including collision protection, overload protection, wind protection, and structural health monitoring. Collision protection prevents the boom and load from colliding with obstacles in the work area; overload protection prevents the lifting weight from exceeding the rated load capacity under current working conditions; wind protection stops operations in extremely high wind speeds to prevent overturning; and structural health monitoring detects abnormal vibrations or fatigue damage in critical components. These functions are typically performed by different types of safety devices, including limit switches, load cells, anemometers, and vibration sensors.

[0003] Currently, the safety protection of stationary rotary cranes mainly adopts a passive protection mode where each device operates independently. The torque limiter alarms or cuts off when the lifting weight approaches or exceeds a fixed threshold; the travel limit switch forcibly stops the corresponding mechanism when it reaches its limit position; and the wind warning is issued to the operator after detection by an anemometer. For collision avoidance, operators assess risks visually, and some cranes are equipped with ultrasonic sensors at the boom end or turntable for proximity alarms. For structural health monitoring, regular shutdowns and maintenance are used for manual inspection of critical components.

[0004] However, this protection mode has significant drawbacks. Regarding collision avoidance, the existing sensors have limited installation locations and detection ranges, failing to cover areas such as the middle of the boom and the rear of the machine room, resulting in parallax and blind spots for operator visual observation. For overload protection, the torque limiter relies on a single fixed threshold, unable to dynamically adapt to the corresponding rated lifting capacity based on real-time changes in the luffing angle for tiered assessment. Regarding structural health monitoring, scheduled shutdowns for maintenance cannot achieve real-time online monitoring during operation, and structural anomalies occurring between maintenance intervals cannot be detected promptly. Furthermore, each safety device operates independently, lacking data exchange and collaborative decision-making mechanisms. All safety judgments and actions ultimately depend on manual handling by the operator; when multiple safety devices alarm simultaneously, the operator must manually assess the risk level and prioritize actions. Summary of the Invention

[0005] In view of this, the purpose of this invention is to propose a multi-dimensional safety protection method and system for fixed rotary cranes, so as to solve the technical problem of unclear overload protection levels in existing cranes.

[0006] The technical means employed in this invention are as follows: A multi-dimensional safety protection method for a fixed rotary crane includes the following steps: S1. Multi-dimensional security detection: The first and second millimeter-wave radars installed on the left and right sides of the boom end, the third and fourth millimeter-wave radars installed on the left and right sides of the middle of the boom, and the fifth and sixth millimeter-wave radars installed on the left and right sides of the rear of the machine room are used to detect whether there is a collision risk in the boom end, the middle of the boom, and the rear of the machine room in the corresponding slewing direction. A laser anti-collision device installed on the lower side of the middle of the boom is used to detect whether there is a risk of collision on the lower surface of the boom when the luffing mechanism performs a dropping action; The weight of the hoisted object is detected by the calibrated main hook load cell and auxiliary hook load cell. The corresponding rated lifting capacity is determined according to the real-time luffing angle and an overload judgment is made. The real-time wind speed in the work area is detected by an anemometer installed on the top of the tower, and strong wind warnings are issued. Vibration data of each key part is collected by vibration monitoring sensors distributed in each key part of the rotary crane, the vibration data is processed and the vibration state of each key part is determined. S2, Security Protection Response: When any detection item in S1 is determined to pose a risk, the dangerous action of the corresponding mechanism is terminated and an alarm signal is issued.

[0007] Furthermore, the first millimeter-wave radar is used to detect the collision risk of the boom end and its vicinity when the slewing mechanism rotates counterclockwise; the second millimeter-wave radar is used to detect the collision risk of the boom end and its vicinity when the slewing mechanism rotates clockwise; the third millimeter-wave radar is used to detect the collision risk of the middle of the boom and its vicinity when the slewing mechanism rotates counterclockwise; the fourth millimeter-wave radar is used to detect the collision risk of the middle of the boom and its vicinity when the slewing mechanism rotates clockwise; the fifth millimeter-wave radar is used to detect the collision risk of the area behind the machine room when the slewing mechanism rotates clockwise; and the sixth millimeter-wave radar is used to detect the collision risk of the area behind the machine room when the slewing mechanism rotates counterclockwise.

[0008] Furthermore, the calibration methods for the main hook load cell and the auxiliary hook load cell are as follows: Use the main hook to lift the main calibration weight, and record the main hook load cell reading E while it is suspended in the air. 主钩1 Place the main calibration weight on the ground and record the value E of the main hook weighing sensor. 主钩2 The system of equations is established as follows: W 主标定砝码 =K×E 主钩1 +b 主 ; 0 = K 主 ×E 主钩2 +b 主 ; The main hook calibration coefficient K is obtained by solving the problem. 主 and calibration correction value b 主 ; Use the secondary hook to lift the secondary calibration weight, and record the value E of the secondary hook weighing sensor while it is suspended in the air. 副钩1 Place the secondary calibration weight on the ground and record the value E of the secondary hook weighing sensor. 副钩2 Establish a system of equations: W 副标定砝码 =K×E 副钩1 +b 副 ; 0 = K 副 ×E 副钩2 +b 副 ; The calibration coefficient K of the secondary hook is obtained by solving the problem. 副 and calibration correction value b 副 .

[0009] After calibration, when the hoisted object is vertically stationary or rising at a constant speed, the actual lifting weight W = K × E + b, where E is the real-time value of the sensor; when the hoisted object is accelerating upwards, the actual lifting weight W = (K × E + b) - (K × E + b) × a 主 ÷g, where a is the upward acceleration and g is the gravitational acceleration.

[0010] Furthermore, the overload determination includes the following steps: When the luffing angle is within the first angle range, the rated lifting capacity of the main hook is the first rated value; When the luffing angle is in the second angle range, the rated lifting capacity of the main hook changes linearly with the luffing angle between the first rated value and the second rated value. When the amplitude angle is less than the first angle range or greater than the second angle range, the main hook is prohibited from lifting objects. An overload alarm will be issued when the actual lifting capacity of the main hook is greater than or equal to 90% of the rated lifting capacity of the main hook but less than or equal to the rated lifting capacity of the main hook. When the actual lifting capacity of the main hook exceeds the rated lifting capacity of the main hook, an overload fault signal is issued.

[0011] Furthermore, the key components include the boom root hinge point, the boom end main hook pulley, the boom end luffing pulley, the tower top hoisting pulley, the tower top luffing pulley, the slewing bearing, the sea-side left portal leg, the sea-side right portal leg, the land-side left portal leg, the land-side right portal leg, the luffing reducer, and the hoisting reducer.

[0012] Furthermore, the specific steps for determining the vibration state of each key component are as follows: When the luffing mechanism is activated, the vibration data at the boom root hinge point, boom end luffing pulley, tower top luffing pulley, sea-side left portal leg, sea-side right portal leg, land-side left portal leg, land-side right portal leg, and luffing reducer are monitored in real time. The real-time vibration amplitude value is compared with the vibration amplitude value during normal operation. Based on the comparison result, it is determined whether the abnormal vibration of the corresponding key parts has reached the alarm level or the fault level. When the hoisting mechanism is in operation, the vibration data of the main hook pulley at the end of the boom, the hoisting pulley at the top of the tower, the left gantry leg on the sea side, the right gantry leg on the sea side, the left gantry leg on the land side, the right gantry leg on the land side, and the hoisting reducer are monitored in real time. The real-time vibration amplitude value is compared with the vibration amplitude value during normal operation. Based on the comparison result, it is determined whether the abnormal vibration of the corresponding key parts has reached the alarm level or the fault level. When the slewing mechanism is in operation, the vibration data of the slewing bearing, the left and right slewing legs on the sea side, the left and right slewing legs on the land side are monitored in real time. The real-time vibration amplitude value is compared with the vibration amplitude value during normal operation. Based on the comparison result, it is determined whether the abnormal vibration of the corresponding key parts has reached the alarm level or the fault level.

[0013] Furthermore, when the real-time vibration amplitude value is greater than or equal to 1.05 times and less than 1.1 times the normal operating vibration amplitude value, the abnormal vibration of the corresponding key part is judged to have reached the alarm level; when the real-time vibration amplitude value is greater than or equal to 1.1 times the normal operating vibration amplitude value, the abnormal vibration of the corresponding key part is judged to have reached the fault level.

[0014] This invention also provides a multi-dimensional safety protection system for a fixed rotary crane, used to implement the multi-dimensional safety protection method for a fixed rotary crane described in any one of the above claims, comprising: The security detection unit includes a first millimeter-wave radar and a second millimeter-wave radar installed on the left and right sides of the boom end, a third millimeter-wave radar and a fourth millimeter-wave radar installed on the left and right sides of the middle of the boom, a fifth millimeter-wave radar and a sixth millimeter-wave radar installed on the left and right sides of the rear of the machine room, a laser anti-collision device installed on the lower side of the middle of the boom, a main hook load cell and a secondary hook load cell installed on the pulley at the boom end, and an anemometer installed on the top of the tower, used to perform the collision risk detection, overload determination and strong wind warning detection as described in claim 1S1; The condition monitoring unit includes vibration monitoring sensors, data collection switches, and condition monitoring host distributed in various key parts of the rotary crane, and is used to perform vibration data acquisition and vibration condition determination as described in claim 1S1. The PLC control unit is used to receive the detection results from the security detection unit and the status monitoring unit. When any detection item is determined to have a risk, the corresponding dangerous action of the mechanism is terminated and an alarm signal is issued.

[0015] Furthermore, the PLC control unit includes a PLC module, a switch, a DI module, and an AI module; the DI module is used to collect detection signals from various millimeter-wave radars and laser anti-collision devices, the AI ​​module is used to collect detection data from the main hook weighing sensor, the auxiliary hook weighing sensor, and the anemometer, and the PLC module receives abnormal vibration signals determined by the status monitoring host via the switch.

[0016] Furthermore, in the condition monitoring unit, each vibration monitoring sensor transmits the detection data to the condition monitoring host via a data aggregation switch. The condition monitoring host processes the detection data and determines the vibration state of each key component, then transmits the determination result to the PLC control unit via the data aggregation switch.

[0017] Compared with the prior art, the present invention has the following advantages: This invention solves the problems of existing sensors only covering the left and right sides of the boom end, the left and right sides of the boom middle, and the left and right sides of the machine room rear. This ensures that the end area, middle area, and rear area of ​​the machine room in both clockwise and counterclockwise rotation directions are covered by radar in their respective directions. Each millimeter-wave radar activates collision risk detection in its corresponding direction when a rotation occurs. Simultaneously, a laser anti-collision device is installed on the lower side of the boom middle to detect obstacles on the lower surface of the boom when the luffing mechanism performs a drop operation. This solves the problems of existing sensors only covering the boom end or a partial area of ​​the turntable, lacking detection coverage in the boom middle and rear of the machine room, and the parallax and blind spots inherent in visual observation by operators.

[0018] In the overload determination process, this invention determines the rated lifting capacity corresponding to the current working condition based on the real-time luffing angle. Different rated lifting capacities are used as determination criteria within different luffing angle ranges, ensuring that the overload determination always matches the actual load-bearing capacity of the crane under the current working condition. Furthermore, a two-level determination system of overload alarm and overload fault is established. When the actual lifting capacity reaches the alarm coefficient of the rated lifting capacity, an alarm is first issued. Only when the actual lifting capacity exceeds the rated lifting capacity is a fault-level shutdown command triggered. This solves the problem that existing torque limiters rely solely on a single fixed threshold for judgment and cannot dynamically adapt to the corresponding rated lifting capacity based on real-time changes in the luffing angle.

[0019] This invention employs vibration monitoring sensors installed at the boom root hinge point, boom end pulley, tower top pulley, slewing bearing, four portal legs, and reducer. During boom luffing mechanism operation, only the luffing-related components are monitored; during hoisting mechanism operation, only the hoisting-related components are monitored; and during slewing mechanism operation, only the slewing-related components are monitored. This allows each sensor to sample specifically according to its corresponding monitoring object during different mechanism operations. The status monitoring host analyzes the collected vibration data and determines the cause based on the deviation between the real-time vibration amplitude and the normal operating vibration amplitude, according to two tiered thresholds: alarm and fault. This solves the problems of the inability to achieve real-time online monitoring during operation and the failure to promptly detect structural anomalies occurring between maintenance intervals using scheduled shutdown maintenance methods. Attached Figure Description

[0020] 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.

[0021] Figure 1 This is a system architecture diagram of the present invention.

[0022] Figure 2 This is a flowchart of the method of the present invention. Detailed Implementation

[0023] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0024] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0025] like Figure 2 As shown, the present invention provides a multi-dimensional safety protection method for a fixed rotary crane, comprising the following steps: Millimeter-wave radar matrix collision detection; The first and second millimeter-wave radars are installed on the left and right sides of the boom end, respectively; the third and fourth millimeter-wave radars are installed on the left and right sides of the middle of the boom, respectively; and the fifth and sixth millimeter-wave radars are installed on the left and right sides of the rear of the machine room, respectively.

[0026] The first millimeter-wave radar activates when the slewing mechanism rotates counterclockwise to detect potential collision risks at the boom end and its vicinity. The second millimeter-wave radar activates when the slewing mechanism rotates clockwise to detect potential collision risks at the boom end and its vicinity. The third millimeter-wave radar activates when the slewing mechanism rotates counterclockwise to detect potential collision risks in the middle of the boom and its vicinity. The fourth millimeter-wave radar activates when the slewing mechanism rotates clockwise to detect potential collision risks in the middle of the boom and its vicinity. The fifth millimeter-wave radar activates when the slewing mechanism rotates clockwise to detect potential collision risks in the area behind the machine room. The sixth millimeter-wave radar activates when the slewing mechanism rotates counterclockwise to detect potential collision risks in the area behind the machine room.

[0027] Each millimeter-wave radar transmits its detection results to the PLC control unit.

[0028] Laser collision avoidance detection; A laser anti-collision device is installed on the lower side of the middle section of the boom. The laser anti-collision device creates a rectangular anti-collision detection area under the boom structure. It is activated when the luffing mechanism performs a dropping action to detect whether there is a collision risk on the lower surface of the boom and transmits the detection results to the PLC control unit.

[0029] Weighing calibration and overload determination; The main hook load cell is installed on the main hook pulley at the end of the boom, and the auxiliary hook load cell is installed on the auxiliary hook pulley at the end of the boom. Both the main hook load cell and the auxiliary hook load cell must be calibrated before use.

[0030] The calibration method for the main hook load cell is as follows: Use the main hook to lift the main calibration weight, hover it in the air, and record the main hook load cell value E. 主钩1 Place the main calibration weight on the ground and record the value E of the main hook weighing sensor. 主钩2 Establish a system of equations: W 主标定砝码 =K×E 主钩1 +b 主 ; 0 = K 主 ×E 主钩2 +b 主 ; The main hook calibration coefficient K is obtained by solving the problem. 主 and calibration correction value b 主 .

[0031] The calibration method for the auxiliary hook load cell is as follows: Use the auxiliary hook to lift the auxiliary calibration weight, suspend it in the air, and record the value E of the auxiliary hook load cell. 副钩1 Place the secondary calibration weight on the ground and record the value E of the secondary hook weighing sensor. 副钩2 Establish a system of equations: W 副标定砝码 =K×E 副钩1 +b 副 ; 0 = K 副 ×E 副钩2 +b 副 ; The calibration coefficient K of the secondary hook is obtained by solving the problem. 副 and calibration correction value b 副 .

[0032] After calibration, the main hook load cell and the auxiliary hook load cell detect the weight of the hoisted object in real time during the hoisting operation and transmit the detection data to the PLC control unit. When the hoisted object is in a vertical static or uniformly rising state, the actual lifting weight W = K × E + b, where E is the real-time value of the sensor; when the hoisted object is in an upward acceleration state, the actual lifting weight W = (K × E + b) - (K × E + b) × a ÷ g, where a is the upward acceleration and g is the gravitational acceleration.

[0033] The PLC control unit determines the rated lifting capacity of the main hook under the current working conditions based on the real-time luffing angle. When the luffing angle is within the first angle range, the rated lifting capacity of the main hook is the first rated value; when the luffing angle is within the second angle range, the rated lifting capacity of the main hook changes linearly with the luffing angle between the first and second rated values; when the luffing angle is less than the first angle range or greater than the second angle range, the main hook is prohibited from lifting objects. The PLC control unit compares the actual lifting capacity with the rated lifting capacity. When the actual lifting capacity of the main hook is greater than or equal to the product of the overload alarm coefficient and the rated lifting capacity of the main hook, but less than or equal to the rated lifting capacity of the main hook, an overload alarm is issued; when the actual lifting capacity of the main hook is greater than the rated lifting capacity of the main hook, an overload fault signal is issued.

[0034] Gale warning detection; An anemometer is installed at the top of the tower. During hoisting operations, the anemometer monitors the real-time wind speed in the work area and transmits the data to the PLC control unit. The PLC control unit issues a strong wind warning signal when the wind speed exceeds a preset threshold.

[0035] Vibration condition monitoring; Vibration monitoring sensors are installed at key locations on the slewing crane, including the boom root hinge point, the main hook pulley at the boom end, the luffing pulley at the boom end, the hoisting pulley at the top of the tower, the luffing pulley at the top of the tower, the slewing bearing, the left and right gantry legs on the sea side, the left and right gantry legs on the land side, the luffing reducer, and the hoisting reducer. The vibration data collected by each sensor is transmitted to the condition monitoring host via a data aggregation switch.

[0036] The status monitoring host processes the received vibration data and determines the vibration status of each key component. When the luffing mechanism operates, it monitors the vibration data from the sensors at the boom root hinge point, the boom end luffing pulley, the tower top luffing pulley, the sea-side left portal leg, the sea-side right portal leg, the land-side left portal leg, the land-side right portal leg, and the luffing reducer in real time, and records the real-time vibration amplitude value K. 实际a Vibration amplitude value K during normal operation 标准a Comparison: When 1.1×K 标准a >K 实际a ≥1.05×K 标准a When K determines that abnormal vibrations in the corresponding key parts have reached the alarm level; 实际a ≥1.1×K 标准a At that time, it is determined that the abnormal vibration of the corresponding key parts has reached the level of a fault.

[0037] When the hoisting mechanism operates, the vibration monitoring sensor data at the main hook pulley at the boom end, the hoisting pulley at the top of the tower, the left and right gantry legs on the sea side, the left and right gantry legs on the land side, and the hoisting reducer are monitored in real time, and the real-time vibration amplitude value K is recorded.实际b Vibration amplitude value K during normal operation 标准b Comparison: When 1.1×K 标准b >K 实际b ≥1.05×K 标准b When K determines that abnormal vibrations in the corresponding key parts have reached the alarm level; 实际b ≥1.1×K 标准b At that time, it is determined that the abnormal vibration of the corresponding key parts has reached the level of a fault.

[0038] When the slewing mechanism operates, the vibration monitoring sensor data at the slewing bearing, the left and right slewing legs on the sea side, the left and right slewing legs on the land side are monitored in real time, and the real-time vibration amplitude value K is recorded. 实际c Vibration amplitude value K during normal operation 标准c Comparison: When 1.1×K 标准c >K 实际c ≥1.05×K 标准c When K determines that abnormal vibrations in the corresponding key parts have reached the alarm level; 实际c ≥1.1×K 标准c At that time, it is determined that the abnormal vibration of the corresponding key parts has reached the level of a fault.

[0039] The status monitoring host transmits the abnormal vibration judgment results of each key part to the PLC control unit through the data aggregation switch.

[0040] S2, Security Protection Response: When any detection item in S1 is deemed to pose a risk, the PLC control unit terminates the dangerous action of the corresponding mechanism and issues an alarm signal. Specifically: when the millimeter-wave radar or laser anti-collision device detects a collision risk, the PLC control unit terminates the operation in the corresponding rotation or luffing direction and issues an anti-collision alarm; when the weighing system determines an overload alarm, the PLC control unit issues an overload alarm prompt; when an overload fault is determined, the PLC control unit terminates the lifting mechanism's rising action and issues an overload fault signal; when the anemometer detects excessively high wind speeds, the PLC control unit issues a strong wind warning signal; when vibration monitoring determines that abnormal vibration has reached the alarm level, the PLC control unit issues a vibration abnormality alarm; when abnormal vibration is determined to reach the fault level, the PLC control unit terminates the operation of the corresponding mechanism and issues a vibration abnormality fault signal.

[0041] Multi-dimensional safety protection system for stationary rotary cranes, such as Figure 1 As shown, it consists of four parts: PLC control unit, drive unit, security detection unit, and status monitoring unit.

[0042] The PLC control unit consists of a PLC module, a switch, a DI module, and an AI module. The DI module acquires detection signals from the millimeter-wave radar and laser anti-collision devices in the security detection unit via hard-wiring. The AI ​​module acquires detection data from the main hook load cell, auxiliary hook load cell, and anemometer in the security detection unit via hard-wiring. The PLC module receives abnormal vibration signals determined by the status monitoring host in the status monitoring unit via the switch. Based on the received detection results, when any detection item is deemed to pose a risk, the PLC module transmits a control command to the drive unit via the switch, terminating the dangerous action of the corresponding mechanism and issuing an alarm signal.

[0043] The drive unit consists of a main hoisting frequency converter, an auxiliary hoisting frequency converter, a luffing frequency converter, a slewing frequency converter, a hook slewing frequency converter, and the main hoisting motor, auxiliary hoisting motor, luffing motor, slewing motor, and hook slewing motor driven by each frequency converter. Each frequency converter receives control commands from the PLC control unit via Ethernet cable using the Profinet protocol and drives the corresponding motor to perform or terminate the corresponding action in a hard-wired manner.

[0044] The security detection unit consists of a first millimeter-wave radar, a second millimeter-wave radar, a third millimeter-wave radar, a fourth millimeter-wave radar, a laser anti-collision device, a main hook load cell, an auxiliary hook load cell, an anemometer, a fifth millimeter-wave radar, and a sixth millimeter-wave radar. Each millimeter-wave radar transmits its detection signal to the DI module of the PLC control unit via hardwiring. The laser anti-collision device also transmits its detection signal to the DI module of the PLC control unit via hardwiring. The main hook load cell and auxiliary hook load cell transmit their detection data to the AI ​​module of the PLC control unit in 4-20mA analog signal format. The anemometer transmits its detection data to the AI ​​module of the PLC control unit in 4-20mA analog signal format.

[0045] The condition monitoring unit consists of vibration monitoring sensors distributed at various key locations, a data aggregation switch, and a condition monitoring host. Each vibration monitoring sensor transmits its detection data via Ethernet cable using the TCP / IP protocol to the condition monitoring host. The condition monitoring host processes the detection data, determines the vibration status of each key location, and transmits the determination results via Ethernet cable using the TCP / IP protocol to the PLC control unit.

[0046] This technology provides a multi-dimensional safety protection method and system for fixed slewing cranes. It achieves full coverage detection of collision risks in all areas of the slewing direction by arranging millimeter-wave radar matrices at the boom end, middle, and rear of the machine room; it achieves anti-collision detection of the lower surface of the boom during luffing and descent using laser anti-collision devices; it achieves accurate overload judgment through load cell calibration and dynamic mapping of luffing angle and rated lifting capacity; it achieves strong wind warning through an anemometer; and it achieves online monitoring and classification of structural anomalies during operation through vibration monitoring sensors distributed in twelve key locations. The judgment results of the above five detection methods are uniformly converged to the PLC control unit to trigger the corresponding safety protection response, so that all safety functions work collaboratively under a unified decision-making framework.

[0047] Example: Taking an 800t stationary rotary crane as an example, this paper explains the control process of the multi-dimensional safety protection method for stationary rotary cranes.

[0048] T1, the stationary rotary crane begins operation, and the multi-dimensional safety protection system is activated.

[0049] T2. Each millimeter-wave radar and laser anti-collision device initiates collision detection. When any of them detects a collision risk, the PLC control unit terminates the dangerous action of the corresponding mechanism and issues an alarm.

[0050] T3. The main hook load cell and the auxiliary hook load cell detect the weight of the hoisted object in real time. The PLC control unit determines the current rated lifting capacity based on the real-time luffing angle and performs overload judgment. When an overload alarm is detected, an alarm prompt is issued. When an overload fault is detected, the hoisting mechanism's lifting action is terminated and a fault signal is issued.

[0051] T4. The anemometer monitors the wind speed in the work area in real time. When the wind speed exceeds the preset threshold, the PLC control unit issues a strong wind warning signal.

[0052] T5. Each vibration monitoring sensor collects vibration data of key parts in real time and transmits it to the status monitoring host via the data aggregation switch. The status monitoring host performs abnormal vibration classification and transmits the judgment result to the PLC control unit. The PLC control unit executes the corresponding alarm or shutdown command according to the judgment result.

[0053] T6. Repeat T2 to T5 until the operation is completed, and then the multi-dimensional safety protection system is turned off.

[0054] 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 multi-dimensional safety protection method for a fixed rotary crane, characterized in that, Includes the following steps: S1. Multi-dimensional security detection: The first and second millimeter-wave radars installed on the left and right sides of the boom end, the third and fourth millimeter-wave radars installed on the left and right sides of the middle of the boom, and the fifth and sixth millimeter-wave radars installed on the left and right sides of the rear of the machine room are used to detect whether there is a collision risk in the boom end, the middle of the boom, and the rear of the machine room in the corresponding slewing direction. A laser anti-collision device installed on the lower side of the middle of the boom is used to detect whether there is a risk of collision on the lower surface of the boom when the luffing mechanism performs a dropping action; The weight of the hoisted object is detected by the calibrated main hook load cell and auxiliary hook load cell. The corresponding rated lifting capacity is determined according to the real-time luffing angle and an overload judgment is made. The real-time wind speed in the work area is detected by an anemometer installed on the top of the tower, and strong wind warnings are issued. Vibration data of each key part is collected by vibration monitoring sensors distributed in each key part of the rotary crane, the vibration data is processed and the vibration state of each key part is determined. S2, Security Protection Response: When any detection item in S1 is determined to pose a risk, the dangerous action of the corresponding mechanism is terminated and an alarm signal is issued.

2. The multi-dimensional safety protection method for a fixed rotary crane according to claim 1, characterized in that, The first millimeter-wave radar is used to detect the collision risk of the boom end and its vicinity when the slewing mechanism rotates counterclockwise; the second millimeter-wave radar is used to detect the collision risk of the boom end and its vicinity when the slewing mechanism rotates clockwise; the third millimeter-wave radar is used to detect the collision risk of the boom middle and its vicinity when the slewing mechanism rotates counterclockwise; the fourth millimeter-wave radar is used to detect the collision risk of the boom middle and its vicinity when the slewing mechanism rotates clockwise; the fifth millimeter-wave radar is used to detect the collision risk of the area behind the machine room when the slewing mechanism rotates clockwise; and the sixth millimeter-wave radar is used to detect the collision risk of the area behind the machine room when the slewing mechanism rotates counterclockwise.

3. The multi-dimensional safety protection method for a fixed rotary crane according to claim 1, characterized in that, The calibration methods for the main hook load cell and the auxiliary hook load cell are as follows: Use the main hook to lift the main calibration weight, and record the main hook load cell reading E while it is suspended in the air. 主钩1 Place the main calibration weight on the ground and record the value E of the main hook weighing sensor. 主钩2 The system of equations is established as follows: W 主标定砝码 =K×E 主钩1 +b 主 ; 0=K 主 ×E 主钩2 +b 主 ; The main hook calibration coefficient K is obtained by solving the problem. 主 and calibration correction value b 主 ; Use the secondary hook to lift the secondary calibration weight, and record the value E of the secondary hook weighing sensor while it is suspended in the air. 副钩1 Place the secondary calibration weight on the ground and record the value E of the secondary hook weighing sensor. 副钩2 Establish a system of equations: W 副标定砝码 =K×E 副钩1 +b 副 ; 0=K 副 ×E 副钩2 +b 副 ; The calibration coefficient K of the secondary hook is obtained by solving the problem. 副 and calibration correction value b 副 . After calibration, when the hoisted object is vertically stationary or rising at a constant speed, the actual lifting weight W = K × E + b, where E is the real-time value of the sensor; when the hoisted object is accelerating upwards, the actual lifting weight W = (K × E + b) - (K × E + b) × a 主 ÷g, where a is the upward acceleration and g is the gravitational acceleration.

4. The multi-dimensional safety protection method for a fixed rotary crane according to claim 3, characterized in that, The overload determination includes the following steps: When the luffing angle is within the first angle range, the rated lifting capacity of the main hook is the first rated value; When the luffing angle is in the second angle range, the rated lifting capacity of the main hook changes linearly with the luffing angle between the first rated value and the second rated value. When the amplitude angle is less than the first angle range or greater than the second angle range, the main hook is prohibited from lifting objects. An overload alarm will be issued when the actual lifting capacity of the main hook is greater than or equal to 90% of the rated lifting capacity of the main hook but less than or equal to the rated lifting capacity of the main hook. When the actual lifting capacity of the main hook exceeds the rated lifting capacity of the main hook, an overload fault signal is issued.

5. The multi-dimensional safety protection method for a fixed rotary crane according to claim 1, characterized in that, The key components include the boom root hinge point, the boom end main hook pulley, the boom end luffing pulley, the tower top hoisting pulley, the tower top luffing pulley, the slewing bearing, the sea-side left portal leg, the sea-side right portal leg, the land-side left portal leg, the land-side right portal leg, the luffing reducer, and the hoisting reducer.

6. The multi-dimensional safety protection method for a fixed rotary crane according to claim 5, characterized in that, The specific steps for determining the vibration state of each key component are as follows: When the luffing mechanism is activated, the vibration data at the boom root hinge point, boom end luffing pulley, tower top luffing pulley, sea-side left portal leg, sea-side right portal leg, land-side left portal leg, land-side right portal leg, and luffing reducer are monitored in real time. The real-time vibration amplitude value is compared with the vibration amplitude value during normal operation. Based on the comparison result, it is determined whether the abnormal vibration of the corresponding key parts has reached the alarm level or the fault level. When the hoisting mechanism is in operation, the vibration data of the main hook pulley at the end of the boom, the hoisting pulley at the top of the tower, the left gantry leg on the sea side, the right gantry leg on the sea side, the left gantry leg on the land side, the right gantry leg on the land side, and the hoisting reducer are monitored in real time. The real-time vibration amplitude value is compared with the vibration amplitude value during normal operation. Based on the comparison result, it is determined whether the abnormal vibration of the corresponding key parts has reached the alarm level or the fault level. When the slewing mechanism is in operation, the vibration data of the slewing bearing, the left and right slewing legs on the sea side, the left and right slewing legs on the land side are monitored in real time. The real-time vibration amplitude value is compared with the vibration amplitude value during normal operation. Based on the comparison result, it is determined whether the abnormal vibration of the corresponding key parts has reached the alarm level or the fault level.

7. The multi-dimensional safety protection method for a fixed rotary crane according to claim 6, characterized in that, When the real-time vibration amplitude value is greater than or equal to 1.05 times and less than 1.1 times the normal operating vibration amplitude value, the abnormal vibration of the corresponding key part is judged to have reached the alarm level; when the real-time vibration amplitude value is greater than or equal to 1.1 times the normal operating vibration amplitude value, the abnormal vibration of the corresponding key part is judged to have reached the fault level.

8. A multi-dimensional safety protection system for a fixed rotary crane, used to implement the multi-dimensional safety protection method for a fixed rotary crane as described in any one of claims 1-7, characterized in that, include: The security detection unit includes a first millimeter-wave radar and a second millimeter-wave radar installed on the left and right sides of the boom end, a third millimeter-wave radar and a fourth millimeter-wave radar installed on the left and right sides of the middle of the boom, a fifth millimeter-wave radar and a sixth millimeter-wave radar installed on the left and right sides of the rear of the machine room, a laser anti-collision device installed on the lower side of the middle of the boom, a main hook load cell and a secondary hook load cell installed on the pulley at the boom end, and an anemometer installed on the top of the tower, used to perform the collision risk detection, overload determination and strong wind warning detection as described in claim 1S1; The condition monitoring unit includes vibration monitoring sensors, data collection switches, and condition monitoring host distributed in various key parts of the rotary crane, and is used to perform vibration data acquisition and vibration condition determination as described in claim 1S1. The PLC control unit is used to receive the detection results from the security detection unit and the status monitoring unit. When any detection item is determined to have a risk, the corresponding dangerous action of the mechanism is terminated and an alarm signal is issued.

9. The multi-dimensional safety protection system for a fixed rotary crane according to claim 8, characterized in that, The PLC control unit includes a PLC module, a switch, a DI module, and an AI module. The DI module is used to collect detection signals from various millimeter-wave radars and laser anti-collision devices. The AI ​​module is used to collect detection data from the main hook weighing sensor, the auxiliary hook weighing sensor, and the anemometer. The PLC module receives abnormal vibration signals determined by the status monitoring host via the switch.

10. The multi-dimensional safety protection system for a fixed rotary crane according to claim 8, characterized in that, In the condition monitoring unit, each vibration monitoring sensor transmits the detection data to the condition monitoring host via a data aggregation switch. The condition monitoring host processes the detection data and determines the vibration status of each key part, and transmits the determination result to the PLC control unit via the data aggregation switch.

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