An intelligent auxiliary control system for a fixed rotary crane

Abstract

The application provides a fixed rotary crane intelligent auxiliary control system, a PLC control unit, including a PLC module and a switch, used for receiving and sending control instructions and detection data; a driving unit, including frequency converters corresponding to each mechanism respectively and motors driven by each frequency converter, used for receiving control instructions of the PLC control unit and driving a lifting mechanism, an amplitude changing mechanism, a rotating mechanism and a hook rotating mechanism to execute actions; a man-machine interaction unit, including an auxiliary operation platform; the auxiliary operation mode selection area is used for an operator to select any one of the following auxiliary operation modes: space displacement, centripetal translation, non-centripetal linear translation, fixed attitude movement, multi-point obstacle avoidance movement and step-by-step movement; the application significantly improves the intrinsic safety, operation precision and comprehensive efficiency of large-tonnage hoisting operation, and reduces the long-term dependence on skilled operators.

Description

Technical Field

[0001] This invention relates to the field of crane control technology, and more particularly to an intelligent auxiliary control system for a stationary rotary crane. Background Technology

[0002] The lifting operations of a stationary slewing crane require the coordinated operation of its hoisting mechanism, luffing mechanism, and slewing mechanism. The hoisting mechanism controls the vertical lifting and lowering of the hook to raise or lower the load; the luffing mechanism adjusts the boom angle to change the working radius; and the slewing mechanism drives the entire crane to rotate to adjust the lifting direction. The combined motion of these three mechanisms determines the hook's trajectory in space. To achieve coordinated control of these three mechanisms, stationary slewing cranes are typically equipped with an auxiliary control system. This system converts the operator's commands into drive signals for each mechanism and provides feedback to the operator on the crane's current motion status and equipment parameters. The core components of the auxiliary control system include an input device for operating commands, a logic processing unit, and a human-machine interface (HMI). The HMI displays the status and sets parameters. Operators observe information such as hook position, mechanism speed, load weight, and boom angle on the screen and input control parameters such as target position coordinates, speed limits, and safety thresholds via buttons or a touchscreen, thus establishing an information exchange channel between the operator and the crane's control system.

[0003] Currently, stationary slewing cranes employ a manual control mode from the operator's cab. Operators control the hoisting, luffing, and slewing mechanisms' directions and speeds via handles on the control panel. The human-machine interface provides real-time feedback on key parameters such as hook height, luffing angle, and slewing angle, allowing operators to determine the hook's spatial position and coordinate the handle operation amplitude and timing of each mechanism based on experience. During precise positioning, repeated jogging of the handles is necessary for fine-tuning the speed, requiring multiple corrections to achieve proper alignment. When the lifting trajectory deviates from the expected path due to differences in mechanism response or external disturbances, operators manually adjust the speeds of each mechanism based on the interface deviation information to bring the hook back to the target path. For complex trajectory operations, operators must decompose the three-dimensional spatial motion into three independent directions: slewing, luffing, and hoisting, and manually coordinate the coupling relationship of each axis's speed. In repetitive lifting tasks, the target position must be reset or the hook manually reset before each operation, making trajectory memory and automatic reproduction impossible.

[0004] The aforementioned assisted control mode, which relies on manual operation combined with a human-machine interface for operational correction, has significant technical flaws. This mode requires operators to manually break down complex hoisting tasks into a sequence of actions for each specific operational need, continuously adjusting the speed coordination between the three mechanisms during movement. When performing movements requiring precise speed matching of multiple mechanisms, such as centripetal and non-centripetal linear translation, manual operation struggles to simultaneously coordinate the speed linkage between luffing and lifting or slewing, and between luffing and lifting, resulting in significant trajectory deviations as the hoisted object deviates from the expected straight or circular path. For fixed-posture movement, operators need to manually compensate for load rotation caused by inertia through the hook slewing mechanism during slewing, but manual compensation is difficult to achieve real-time and precise matching with the slewing speed. When obstacles exist in the work path, operators need to manually plan waypoints and break the entire path into multiple independent operations, resetting parameters after each segment before proceeding to the next, resulting in a cumbersome and inconsistent process. For operations requiring precise alignment over short distances, operators can only make tentative adjustments by repeatedly jogging the handle. After each adjustment, they must wait for the mechanism to come to a complete stop and read the positional deviation from the interface before making the next adjustment. This process is time-consuming and physically demanding. Furthermore, existing human-machine interfaces only provide basic operational status displays, with only an indicator area. The interface does not offer auxiliary mode selection based on the type of work scenario, and operators cannot trigger the system to automatically complete the entire lifting process, including the coordinated movement of multiple mechanisms, with a single setting. This results in high labor intensity, low operational efficiency, and the final lifting accuracy is highly dependent on the operator's handle control skills and experience. Summary of the Invention

[0005] In view of this, the purpose of this invention is to propose an intelligent auxiliary control system for a fixed slewing crane to solve the technical problem that existing systems cannot simultaneously coordinate luffing and hoisting or slewing, or the speed linkage between luffing and hoisting.

[0006] The technical means employed in this invention are as follows: A smart auxiliary control system for a stationary rotary crane includes: The PLC control unit, including the PLC module and the switch, is used to receive and send control commands and detection data. The drive unit includes frequency converters corresponding to each mechanism and motors driven by each frequency converter, and is used to receive control commands from the PLC control unit and drive the hoisting mechanism, luffing mechanism, slewing mechanism and hook slewing mechanism of the rotary crane to perform actions. The security detection unit includes several millimeter-wave radars, which are used to collect safety detection data during hoisting operations and transmit it to the PLC control unit; The pose detection unit is used to collect the position and attitude data of the hoisted object and the working environment and transmit them to the PLC control unit. The human-machine interaction unit includes an auxiliary operation platform, which is provided with an auxiliary operation mode selection area and a target crane movement setting area; The auxiliary operation mode selection area is used for operators to select any one of the following auxiliary operation modes: spatial displacement, centripetal translation, non-centripetal linear translation, fixed posture movement, multi-point obstacle avoidance movement and stepping movement. The target hoisting motion setting area is used for operators to input the spatial coordinates of the target position; The PLC control unit, based on the auxiliary operation mode instructions and target position data issued by the human-machine interaction unit, and combined with the detection data from the posture detection unit and the security detection unit, controls the drive unit to drive each mechanism to perform corresponding auxiliary lifting operations.

[0007] Furthermore, the human-machine interaction unit also includes a driver's cab switch. The auxiliary operation platform is connected to the PLC control unit via the driver's cab switch. The auxiliary operation platform sends the intelligent auxiliary operation instructions set by the operator to the PLC control unit using the TCP / IP protocol.

[0008] Furthermore, when the auxiliary operation mode is spatial displacement, the PLC control unit automatically controls the operation of the luffing mechanism, slewing mechanism, and hoisting mechanism based on the initial spatial coordinates P0 (x0, y0, z0) and the target spatial coordinates P1 (x1, y1, z1) of the hoisted object, thereby realizing the spatial displacement of the hoisted object from the initial position to the target position. The specific control method is as follows: The required operating angle for the rotary mechanism is: θ 回转 =arctan(y0÷x0)-arctan(y1÷x1); The required operating angle for the amplitude-changing mechanism is: θ 变幅 =arccos( ÷L)-arccos( ÷L); The required operating height for the hoisting mechanism is: H 起升 =z1-z0 - ; Where L is the boom length; The PLC control unit calculates the required operating angles of the slewing mechanism, the luffing mechanism, and the hoisting mechanism, and controls the slewing mechanism, luffing mechanism, and hoisting mechanism to operate simultaneously according to the calculation results, thereby realizing the spatial displacement of the hoisted object from the starting position to the target position.

[0009] Furthermore, when the auxiliary operation mode is centripetal translation, the slewing mechanism maintains its current angle, and the PLC control unit controls the operation of the luffing mechanism and the hoisting mechanism to achieve a constant-height translational movement of the hoisted object along the boom structure direction. The specific control method is as follows: The linear velocity setpoint for the luffing mechanism is: V 变幅 =V 变幅额 ; The hoisting mechanism speed setpoint is: V h =-L×cosθ×ω 变幅 V h修订 ; Among them, V 变幅额 ω is the rated linear velocity of the luffing mechanism, L is the boom length, θ is the luffing angle measured by the inclinometer in the pose detection unit, and ω is the luffing angle. 变幅额 V is the rated angular velocity of the luffing mechanism. h修订 The hoisting mechanism speed is revised based on the deviation of the hoisting height value measured by the posture detection unit from the corresponding value. Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected centripetal translation auxiliary operation mode, the PLC control unit automatically calculates the required operating angle of the luffing mechanism and the required operating height of the hoisting mechanism for the centripetal translation auxiliary operation. Based on the spatial trajectory of the centripetal translation operation, it calculates the required linear velocity setpoints of the luffing mechanism and the hoisting mechanism during the centripetal translation auxiliary operation control process. Then, the PLC control unit controls the drive unit to complete the corresponding actions according to the calculated linear velocity setpoints of the luffing mechanism and the hoisting mechanism, so as to realize the same height translation movement of the hoisted object from the starting position to the target object along the boom structure direction.

[0010] Furthermore, when the auxiliary operation mode is non-centripetal linear translation, the PLC control unit controls the operation of the luffing mechanism, slewing mechanism, and hoisting mechanism to achieve constant-height translational movement of the hoisted object along any straight line direction. The specific control method is as follows: The linear velocity setpoint for the luffing mechanism is: V 变幅 =V 变幅额 ; The given value for the angular velocity of the rotary mechanism is: ω 回转 = ; The hoisting mechanism speed setpoint is: V h =-L×cosθ×ω 变幅 V h修订 ; Among them, V 变幅额 υ is the rated linear velocity of the luffing mechanism. 变幅 α is the luffing speed, φ is the angle of the linear trajectory, R is the horizontal distance of the hoisted object from the center of rotation, L is the boom length, θ is the luffing angle measured by the tilt meter in the pose detection unit, and ω is the luffing angle. 变幅 V is the angular velocity of the amplitude-changing mechanism. h修订 To correct the hoisting mechanism speed value based on the deviation of the hoisting height value measured by the pose detection unit from the actual hoisting height value, V h额定 The rated speed of the hoisting mechanism; Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected non-centripetal linear translation auxiliary operation mode, the PLC control unit automatically calculates the required operating angles of the slewing mechanism, the luffing mechanism, and the hoisting mechanism for the non-centripetal linear translation auxiliary operation. Based on the spatial trajectory of the non-centripetal linear translation operation, it calculates the required angular velocity setpoints for the slewing mechanism, the linear velocity setpoints for the luffing mechanism, and the speed setpoints for the hoisting mechanism during the non-centripetal linear translation auxiliary operation control process. Then, the PLC control unit controls the drive unit to complete the corresponding actions according to the calculated angular velocity setpoints for the slewing mechanism, the linear velocity setpoints for the luffing mechanism, and the speed setpoints for the hoisting mechanism, achieving a constant-height translational movement of the hoisted object from the starting position to the target object along any straight line direction.

[0011] Furthermore, when the auxiliary operation mode is fixed-posture movement, the PLC control unit controls the hook slewing mechanism to operate in reverse speed matching with the slewing mechanism during the operation of the slewing mechanism, so as to maintain the posture of the hoisted object unchanged during the slewing process. The specific control method is as follows: The setpoint for the speed of the hook slewing mechanism is: V 吊钩 = -V 回转 ×N 吊钩 ÷N 回转 ; Among them, V 回转 N is the operating speed of the rotary mechanism. 吊钩 N is the numerical ratio of the hook's rotational speed to its angular velocity. 回转 This refers to the numerical ratio of the speed and angular velocity of the rotary mechanism; Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected fixed-posture movement assisted operation mode, the PLC control unit automatically calculates the setpoint speed of the hook slewing mechanism required for the fixed-posture movement assisted operation. Then, the PLC control unit controls the drive unit to complete the corresponding action according to the calculated setpoint speed of the hook slewing mechanism, ensuring that the posture of the hoisted object remains unchanged during the slewing process.

[0012] Furthermore, when the auxiliary operation mode is multi-point obstacle avoidance movement, when there is an obstacle on the path of the hoisted object from the starting position to the target position, the PLC control unit automatically adds a path point between the starting position and the target position, and sequentially selects spatial displacement, centripetal translation or non-centripetal linear translation auxiliary control actions to enable the hoisted object to automatically avoid obstacles during the hoisting process.

[0013] Furthermore, when the auxiliary operation mode is step-by-step movement, the PLC control unit controls the hoisting mechanism, luffing mechanism, slewing mechanism and hook slewing mechanism to perform speed control according to the step alignment distance value entered by the operator, so as to achieve short-distance precise alignment of the hoisted object.

[0014] Furthermore, the pose detection unit includes a laser scanner and a high-definition camera installed at the end of the boom, as well as a point cloud processing server and an image processing server installed in the PLC room. The laser scanner is used to collect point cloud data of the working area under the rotary crane and transmit it to the point cloud processing server. The point cloud processing server obtains real-time location data of the hoisted object and the working environment by performing calculations on the point cloud data. The high-definition camera is used to collect image data of the working area under the slewing crane and transmit it to the image processing server. The image processing server obtains the real-time posture data of the hoisted object by performing calculations on the image data.

[0015] Furthermore, the PLC control unit also includes 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 in the security detection unit. The PLC module receives the detection signals collected by the DI module for anti-collision protection. The AI ​​module is used to collect detection data from the main hook weighing sensor, the auxiliary hook weighing sensor, and the anemometer in the security detection unit. The PLC module receives the detection data collected by the AI ​​module and is used for overload protection and wind protection. The PLC module receives detection data from the main lifting encoder, auxiliary lifting encoder, inclinometer, Gray busbar encoder, and hook slewing encoder in the pose detection unit via a switch, and uses this data to acquire the main lifting height, auxiliary lifting height, luffing angle, slewing angle, and main hook slewing angle.

[0016] Compared with the prior art, the present invention has the following advantages: This invention establishes an auxiliary operation mode selection area and a target hoisting motion setting area on the auxiliary operation platform of the human-machine interface unit. Operators only need to select the desired auxiliary operation mode in the mode selection area and enter the spatial coordinates of the target position in the target hoisting motion setting area. The system then automatically controls each mechanism to execute the corresponding auxiliary operation actions. This frees operators from the complex operation of simultaneously manipulating three handles: hoisting, luffing, and slewing. Operators no longer need to determine the direction and speed coordination of each mechanism based on visual observation and experience. They only need to complete two steps—mode selection and coordinate entry—to trigger the system to automatically execute the entire hoisting process, reducing operational difficulty and long-term reliance on skilled operators.

[0017] In the spatial displacement mode, this invention calculates the required operating angles for the slewing mechanism, the luffing mechanism, and the hoisting mechanism based on the initial and target spatial coordinates of the hoisted object. This allows the three mechanisms to operate simultaneously according to their respective required movements, moving directly from the starting position to the target position without manual intervention. The mechanisms automatically coordinate and cooperate during the movement, continuously moving the hoisted object along the planned path to the target position. This eliminates the need for operators to repeatedly adjust the object in segments by pressing handles, thus reducing the total time required for hoisting and positioning.

[0018] In the centripetal translation mode, the slewing mechanism maintains its current angle, the luffing mechanism operates at its rated linear speed, and the hoisting mechanism compensates for the height change of the hoisted object caused by the luffing motion, ensuring that the hoisted object moves at a constant height along the boom structure. In the non-centripetal linear translation mode, the system calculates the required operating amounts of the slewing mechanism, luffing mechanism, and hoisting mechanism, and determines the angular velocity setpoint of the slewing mechanism based on the angle of the running straight trajectory and the current angle of the slewing mechanism, ensuring that the hoisted object moves at a constant height along a straight trajectory in any set direction. In both modes, the speed compensation of the hoisting mechanism is determined based on the boom length, luffing angle, luffing mechanism angular velocity, and the revised value corresponding to the height deviation of the hoisted object. This ensures that the height change caused by the luffing motion is offset by the hoisting mechanism in real time, and the hoisted object remains within the same height plane throughout the translation process. This solves the problem of manual operation struggling to coordinate the speed matching relationships of multiple mechanisms simultaneously, leading to the hoisted object deviating from the expected trajectory. Attached Figure Description

[0019] 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.

[0020] Figure 1 This is the wiring diagram for the PLC control unit of the present invention.

[0021] Figure 2 This is a wiring diagram of the drive unit of the present invention.

[0022] Figure 3 This is the wiring diagram of the security detection unit of the present invention.

[0023] Figure 4 This is the wiring diagram of the pose detection unit of the present invention.

[0024] Figure 5 This is the control flowchart of the present invention. Detailed Implementation

[0025] 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.

[0026] 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.

[0027] This invention provides an intelligent auxiliary control system for a fixed rotary crane, comprising: It consists of five parts: PLC control unit, drive unit, security detection unit, posture detection unit, and human-computer interaction unit.

[0028] The PLC control unit consists of a PLC module, a switch, a DI module, and an AI module installed in the PLC room. The PLC module transmits control commands via a switch to the main hoisting inverter, auxiliary hoisting inverter, luffing inverter, slewing inverter, and hook slewing inverter in the drive unit, thereby controlling the main hook, auxiliary hook, luffing, slewing, and main hook slewing actions. The PLC module also receives positioning and attitude detection data from the point cloud processing server and image processing server in the pose detection unit via the switch, used for determining safety during hoisting operations. Furthermore, the PLC module receives detection data from the main hoisting encoder, auxiliary hoisting encoder, inclinometer, Gray busbar encoder, and hook slewing encoder in the pose detection unit via the switch, used to obtain and calculate the main hoisting height, auxiliary hoisting height, luffing angle, slewing angle, and main hook slewing angle of the slewing crane. Finally, the PLC module receives intelligent auxiliary operation commands from the auxiliary operation platform in the human-machine interface unit via the switch, used for intelligent auxiliary action control of multi-mechanism collaboration. Finally, the PLC module receives data from the first millimeter-wave radar, second millimeter-wave radar, and third millimeter-wave radar in the security detection unit collected by the DI module. The system includes six millimeter-wave radars: a first-wave radar, a second-wave radar, a laser anti-collision device, a fifth-wave radar, and a sixth-wave radar, used for collision protection during hoisting operations. The PLC module receives data from the main hook weighing sensor, auxiliary hook weighing sensor, and anemometer in the security detection unit, collected by the AI ​​module, for overload and wind protection during hoisting operations. The PLC module also receives abnormal vibration signals from key parts of the slewing crane as determined by the status monitoring host in the security detection unit via a switch, used to suppress abnormal vibrations. The switch establishes a data transmission link between the PLC control unit and the drive unit, security detection unit, posture detection unit, and human-machine interface unit. The DI module collects detection signals from the first, second, third, fourth, laser anti-collision device, fifth, and sixth millimeter-wave radars in the security detection unit. The AI ​​module collects detection data from the main hook weighing sensor, auxiliary hook weighing sensor, and anemometer in the security detection unit.

[0029] The drive unit consists of a main hoisting frequency converter, an auxiliary hoisting frequency converter, an luffing frequency converter, a slewing frequency converter, a hook forward slewing contactor, a hook reverse slewing contactor, a main hoisting motor, an auxiliary hoisting motor, a luffing motor, a slewing motor, and a hook slewing motor. The main hoisting inverter uses the Profinet protocol to receive control commands from the PLC control unit via Ethernet cable, and then drives the main hoisting motor in a hard-wired manner. The auxiliary hoisting inverter uses the Profinet protocol to receive control commands from the PLC control unit via Ethernet cable, and then drives the auxiliary hoisting motor in a hard-wired manner. The luffing inverter uses the Profinet protocol to receive control commands from the PLC control unit via Ethernet cable, and then drives the luffing motor in a hard-wired manner. The slewing inverter uses the Profinet protocol to receive control commands from the PLC control unit via Ethernet cable, and then drives the slewing motor in a hard-wired manner. The hook slewing inverter uses the Profinet protocol to receive control commands from the PLC control unit via Ethernet cable, and then drives the hook slewing motor in a hard-wired manner. Specific wiring is as follows: Figure 2 As shown.

[0030] 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 weighing sensor, an auxiliary hook weighing sensor, an anemometer, a fifth millimeter-wave radar, a sixth millimeter-wave radar, a status monitoring host, a data aggregation switch, and vibration monitoring sensors for each key component. Specifically, the first millimeter-wave radar transmits its signal to the DI module in the PLC control unit via hardwiring; the second millimeter-wave radar transmits its signal to the DI module in the PLC control unit via hardwiring; the third millimeter-wave radar transmits its signal to the DI module in the PLC control unit via hardwiring; the fourth millimeter-wave radar transmits its signal to the DI module in the PLC control unit via hardwiring; the laser anti-collision device transmits its signal to the DI module in the PLC control unit via hardwiring; the main hook load cell transmits its 4-20mA detection data to the AI ​​module in the PLC control unit via hardwiring; the auxiliary hook load cell transmits its 4-20mA detection data to the AI ​​module in the PLC control unit via hardwiring; the anemometer transmits its 4-20mA detection data to the AI ​​module in the PLC control unit via hardwiring; and the fifth millimeter-wave radar transmits its signal to the AI ​​module in the PLC control unit via hardwiring. The system transmits signals to the DI module in the PLC control unit via a hard-wired connection. The condition monitoring host receives vibration data from the sensors at key locations via Ethernet cable through a data aggregation switch using the TCP / IP protocol. It also transmits the abnormal vibration judgment results from each key location to the PLC control unit via the same TCP / IP protocol and Ethernet cable. The data aggregation switch supports the TCP / IP protocol, aggregating the vibration data from the sensors at key locations via Ethernet cable and transmitting it to the condition monitoring host. Simultaneously, it establishes a data transmission link between the security detection unit and the PLC control unit via Ethernet cable using the TCP / IP protocol. The vibration sensors at key locations transmit their detection data to the condition monitoring host via the data aggregation switch using the same TCP / IP protocol and Ethernet cable.

[0031] The pose detection unit consists of a laser scanner, a high-definition camera, a point cloud processing server, an image processing server, a main lifting encoder, a secondary lifting encoder, an inclinometer, a Gray busbar encoder, and a hook rotary encoder. The system comprises the following components: a laser scanner transmits its acquired point cloud data to a point cloud processing server via Ethernet using the TCP / IP protocol; a high-definition camera transmits its acquired image data to an image processing server via Ethernet using the TCP / IP protocol; the point cloud processing server transmits its processed positioning data to a PLC control unit via Ethernet using the TCP / IP protocol; the image processing server transmits its processed attitude data to a PLC control unit via Ethernet using the TCP / IP protocol; the main lifting encoder transmits its detection data to a PLC control unit via Ethernet using the Profinet protocol; the auxiliary lifting encoder transmits its detection data to a PLC control unit via Ethernet using the Profinet protocol; the inclinometer transmits its detection data to a PLC control unit via Ethernet using the Profinet protocol; the Gray busbar encoder transmits its detection data to a PLC control unit via Ethernet using the Profinet protocol; and the hook rotary encoder transmits its detection data to a PLC control unit via Ethernet using the Profinet protocol. Specific wiring details are as follows: Figure 4 As shown.

[0032] The human-machine interface unit consists of an auxiliary operation platform and a driver's cab switch. The auxiliary operation platform uses the TCP / IP protocol to send the intelligent auxiliary operation commands set by the operator to the PLC control unit via Ethernet cable.

[0033] The specific interface of the auxiliary operation platform is as follows: Figure 5 As shown, the specific functions are described below.

[0034] The auxiliary operation functions are accessed through the human-machine interface. Operators can select the desired auxiliary operation mode (such as spatial displacement, centripetal translation, non-centripetal linear translation, fixed-posture movement, multi-point obstacle avoidance movement, or stepping movement) in the auxiliary operation mode selection area of ​​this interface. Then, the operator enters the desired spatial position in the target lifting motion setting area of ​​the human-machine interface. The system will then automatically control the various mechanisms of the fixed slewing crane to execute the corresponding auxiliary operation actions. The control methods for each auxiliary operation mode are explained below: ① Spatial displacement This auxiliary control mode is applied to auxiliary operations where the object to be hoisted needs to be automatically moved from the starting position to the target position. The system automatically controls the luffing mechanism, slewing mechanism, and hoisting mechanism based on the spatial coordinates P0 (x0, y0, z0) of the starting position and P1 (x1, y1, z1) of the target position to achieve spatial displacement of the object. The specific control methods for the luffing mechanism, slewing mechanism, and hoisting mechanism are as follows: The required operating angle θ of the rotary mechanism 回转 =arctan(y0÷x0)-arctan(y1÷x1); The required operating angle θ of the luffing mechanism 变幅 =arccos( ÷L)-arccos( ÷L); Required operating height H of the hoisting mechanism 起升 =z1-z0 - ; Where L is the boom length.

[0035] The luffing mechanism, slewing mechanism, and hoisting mechanism control their speeds according to their respective required operating angles or heights to achieve spatial displacement of the hoisted object.

[0036] ②Centric translation This mode is applied to fixed rotary cranes where the rotation angle remains constant, and the hoisted object moves horizontally along the boom structure at a constant height. The operator inputs the desired horizontal movement position, and the system automatically controls the luffing and hoisting mechanisms to achieve the centripetal horizontal movement of the hoisted object. To ensure the centripetal, upward horizontal movement of the hoisted object, the specific control methods for the luffing and hoisting mechanisms are as follows: The required operating angle θ for the amplitude-changing mechanism 变幅 Required operating height H of the lifting mechanism 起升 The calculation method is the same as ① spatial shift.

[0037] luffing mechanism linear velocity setpoint V 变幅 =V 变幅额 ; Hoisting mechanism speed setpoint V h =-L×cosθ×ω 变幅 V h修订 ; Among them, V 变幅额 ω is the rated linear velocity of the luffing mechanism, L is the boom length, θ is the luffing angle measured by the inclinometer in the pose detection unit, and ω is the luffing angle. 变幅额 V is the rated angular velocity of the luffing mechanism. h修订 This is a revised value for the hoisting mechanism speed based on the deviation of the hoisting height value measured by the posture detection unit.

[0038] Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected centripetal translation auxiliary operation mode, the PLC control unit automatically calculates the required operating angle of the luffing mechanism and the required operating height of the hoisting mechanism for the centripetal translation auxiliary operation. Based on the spatial trajectory of the centripetal translation operation, it calculates the required linear velocity setpoints of the luffing mechanism and the hoisting mechanism during the centripetal translation auxiliary operation control process. Then, the PLC control unit controls the drive unit to complete the corresponding actions according to the calculated linear velocity setpoints of the luffing mechanism and the hoisting mechanism, so as to realize the same height translation movement of the hoisted object from the starting position to the target object along the boom structure direction.

[0039] ③ Non-centripetal linear translation This mode is used when the hoisted object needs to be moved horizontally along any straight line at the same height. The operator inputs the desired horizontal position, and the system automatically controls the luffing mechanism, slewing mechanism, and hoisting mechanism to achieve non-centripetal linear translation of the hoisted object. To ensure non-centripetal linear translation, the specific control methods for the luffing mechanism, slewing mechanism, and hoisting mechanism are as follows: The required operating angle θ for the rotary mechanism 回转 The required operating angle θ of the luffing mechanism 变幅 Required operating height H of the lifting mechanism 起升 The calculation method is the same as ① spatial shift.

[0040] luffing mechanism linear velocity setpoint V 变幅 =V 变幅额 ; angular velocity setpoint ω of the rotary mechanism 回转 = ; Hoisting mechanism speed setpoint V h =-L×cosθ×ω 变幅 V h修订 ; Among them, V 变幅额 υ is the rated linear velocity of the luffing mechanism. 变幅 α is the luffing speed, φ is the angle of the linear trajectory, R is the horizontal distance of the hoisted object from the center of rotation, L is the boom length, θ is the luffing angle measured by the tilt meter in the pose detection unit, and ω is the luffing angle. 变幅 V is the angular velocity of the amplitude-changing mechanism. h修订 The hoisting mechanism speed is revised based on the deviation of the hoisting height value measured by the posture detection unit from the actual hoisting height value (value taken as ±3% × V). h额定 ), V h额定 This is the rated speed of the lifting mechanism.

[0041] Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected non-centripetal linear translation auxiliary operation mode, the PLC control unit automatically calculates the required operating angles of the slewing mechanism, the luffing mechanism, and the hoisting mechanism for the non-centripetal linear translation auxiliary operation. Based on the spatial trajectory of the non-centripetal linear translation operation, it calculates the required angular velocity setpoints for the slewing mechanism, the linear velocity setpoints for the luffing mechanism, and the speed setpoints for the hoisting mechanism during the non-centripetal linear translation auxiliary operation control process. Then, the PLC control unit controls the drive unit to complete the corresponding actions according to the calculated angular velocity setpoints for the slewing mechanism, the linear velocity setpoints for the luffing mechanism, and the speed setpoints for the hoisting mechanism, achieving a constant-height translational movement of the hoisted object from the starting position to the target object along any straight line direction.

[0042] ④ Fixed posture movement When the slewing mechanism of a stationary rotary crane is in operation, the load will rotate to overcome inertia. This fixed-posture movement mode can be achieved during lifting by intelligently matching the speed control of the hook slewing mechanism with that of the slewing mechanism. The specific control method is as follows: The given speed V of the hook slewing mechanism 吊钩 = -V 回转 ×N 吊钩 ÷N 回转 ; Among them, V 回转 N is the operating speed of the rotary mechanism. 吊钩 N is the numerical ratio of the hook's rotational speed to its angular velocity. 回转 This is the numerical ratio of the speed and angular velocity of the rotary mechanism.

[0043] Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected fixed-posture movement assisted operation mode, the PLC control unit automatically calculates the setpoint speed of the hook slewing mechanism required for the fixed-posture movement assisted operation. Then, the PLC control unit controls the drive unit to complete the corresponding action according to the calculated setpoint speed of the hook slewing mechanism, ensuring that the posture of the hoisted object remains unchanged during the slewing process.

[0044] ⑤ Multi-point obstacle avoidance movement This mode is used as an auxiliary operation when there are obstacles that pose a risk of collision between the starting position and the target position of the hoisted object. The system can automatically add the path points between the starting position A and the target position D, and automatically select the above-mentioned auxiliary control actions such as spatial displacement, centripetal translation, and non-centripetal linear translation to automatically avoid obstacles during hoisting.

[0045] When the multi-point obstacle avoidance movement mode is triggered and the PLC control unit determines that there is an obstacle on the planned path of the hoisted object from the starting position to the target position, the PLC control unit automatically inserts at least one waypoint between the starting position and the target position, with the minimum clearance between the hoisted object and the obstacle not less than 0.5m as a safety constraint and the shortest total hoisting time as an efficiency optimization goal. Based on the planned hoisting path through the waypoint, the PLC control unit sequentially selects the appropriate action from three auxiliary control actions: spatial displacement, centripetal translation, and non-centripetal linear translation, so that the hoisted object automatically avoids the obstacle during the hoisting process.

[0046] ⑥ Step-by-step movement This mode is used as an auxiliary operation when there is a need for precise alignment of the hoisted object over a short distance. The operator enters the required precise step alignment distance value, and the system automatically controls the speed of each mechanism according to the entered distance value.

[0047] This invention will be used in the slewing crane project produced by the Port Machinery Division of Dalian Huarui Heavy Industry Group Co., Ltd.

[0048] The development of an intelligent auxiliary control system for stationary slewing cranes has greatly enhanced the core competitiveness of slewing crane products in the market. Meanwhile, the cost of a single set of the intelligent auxiliary control system for stationary slewing cranes is 800,000 yuan. Based on the Port Machinery Division's annual production of 5 slewing cranes equipped with this system, it can increase the company's annual output value by 4 million yuan.

[0049] Example: Taking an 800t stationary rotary crane as an example, the control process of the intelligent auxiliary control system for stationary rotary cranes is explained: Step 1: The stationary rotary crane begins operation, and the intelligent auxiliary control system is activated; Step 2: The position and posture detection unit starts working, acquiring the positioning and posture detection data of the hoisted object, as well as the real-time height values ​​of the main hook, auxiliary hook, luffing angle, slewing angle, and main hook. Step 3: Based on the auxiliary control commands entered by the human-computer interaction unit, perform intelligent auxiliary control of the corresponding mechanism; Step 4: When the security detection unit issues a risk warning, the operation of the corresponding mechanism is terminated, an alarm is issued, and manual intervention is initiated. Step 5: After manual intervention is completed, the human-machine interaction unit re-enters the various auxiliary control commands to perform intelligent auxiliary control of the corresponding mechanisms; Step Six: Repeat steps two through five until the task is completed, then turn off the intelligent auxiliary control system.

[0050] 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. An intelligent auxiliary control system for a fixed rotary crane, characterized in that, include: The PLC control unit, including the PLC module and the switch, is used to receive and send control commands and detection data. The drive unit includes frequency converters corresponding to each mechanism and motors driven by each frequency converter, and is used to receive control commands from the PLC control unit and drive the hoisting mechanism, luffing mechanism, slewing mechanism and hook slewing mechanism of the rotary crane to perform actions. The security detection unit includes several millimeter-wave radars, which are used to collect safety detection data during hoisting operations and transmit it to the PLC control unit; The pose detection unit is used to collect the position and attitude data of the hoisted object and the working environment and transmit them to the PLC control unit. The human-machine interaction unit includes an auxiliary operation platform, which is provided with an auxiliary operation mode selection area and a target crane movement setting area; The auxiliary operation mode selection area is used for operators to select any one of the following auxiliary operation modes: spatial displacement, centripetal translation, non-centripetal linear translation, fixed posture movement, multi-point obstacle avoidance movement and stepping movement. The target hoisting motion setting area is used for operators to input the spatial coordinates of the target position; The PLC control unit, based on the auxiliary operation mode instructions and target position data issued by the human-machine interaction unit, and combined with the detection data from the posture detection unit and the security detection unit, controls the drive unit to drive each mechanism to perform corresponding auxiliary lifting operations.

2. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, The human-machine interaction unit also includes a driver's cab switch. The auxiliary operation platform is connected to the PLC control unit via the driver's cab switch. The auxiliary operation platform sends the intelligent auxiliary operation instructions set by the operator to the PLC control unit using the TCP / IP protocol.

3. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, When the auxiliary operation mode is spatial displacement, the PLC control unit automatically controls the operation of the luffing mechanism, slewing mechanism, and hoisting mechanism based on the initial spatial coordinates P0 (x0, y0, z0) and the target spatial coordinates P1 (x1, y1, z1) of the hoisted object, thereby realizing the spatial displacement of the hoisted object from the initial position to the target position. The specific control method is as follows: The required operating angle for the rotary mechanism is: θ 回转 =arctan(y0÷x0)-arctan(y1÷x1); The required operating angle for the amplitude-changing mechanism is: θ 变幅 =arccos( ÷L)-arccos( ÷L); The required operating height for the hoisting mechanism is: H 起升 =z1-z0 - ; Where L is the boom length; The PLC control unit calculates the required operating angles of the slewing mechanism, the luffing mechanism, and the hoisting mechanism, and controls the slewing mechanism, luffing mechanism, and hoisting mechanism to operate simultaneously according to the calculation results, thereby realizing the spatial displacement of the hoisted object from the starting position to the target position.

4. The intelligent auxiliary control system for a fixed rotary crane according to claim 3, characterized in that, When the auxiliary operation mode is centripetal translation, the slewing mechanism maintains its current angle, and the PLC control unit controls the operation of the luffing mechanism and the hoisting mechanism to achieve a constant-height translational movement of the hoisted object along the boom structure direction. The specific control method is as follows: The linear velocity setpoint for the luffing mechanism is: V 变幅 =V 变幅额 ; The hoisting mechanism speed setpoint is: V h =-L×cosθ×ω 变幅 V h修订 ; Among them, V 变幅额 ω is the rated linear velocity of the luffing mechanism, L is the boom length, θ is the luffing angle measured by the inclinometer in the pose detection unit, and ω is the luffing angle. 变幅额 V is the rated angular velocity of the luffing mechanism. h修订 The hoisting mechanism speed is revised based on the deviation of the hoisting height value measured by the posture detection unit from the corresponding value. Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected centripetal translation auxiliary operation mode, the PLC control unit automatically calculates the required operating angle of the luffing mechanism and the required operating height of the hoisting mechanism for the centripetal translation auxiliary operation. Based on the spatial trajectory of the centripetal translation operation, it calculates the required linear velocity setpoints of the luffing mechanism and the hoisting mechanism during the centripetal translation auxiliary operation control process. Then, the PLC control unit controls the drive unit to complete the corresponding actions according to the calculated linear velocity setpoints of the luffing mechanism and the hoisting mechanism, so as to realize the same height translation movement of the hoisted object from the starting position to the target object along the boom structure direction.

5. The intelligent auxiliary control system for a fixed rotary crane according to claim 3, characterized in that, When the auxiliary operation mode is non-centripetal linear translation, the PLC control unit controls the operation of the luffing mechanism, slewing mechanism, and hoisting mechanism to achieve constant-height translation of the hoisted object along any straight line direction. The specific control method is as follows: The linear velocity setpoint for the luffing mechanism is: V 变幅 =V 变幅额 ; The given value for the angular velocity of the rotary mechanism is: ω 回转 = ; The hoisting mechanism speed setpoint is: V h =-L×cosθ×ω 变幅 V h修订 ; Among them, V 变幅额 υ is the rated linear velocity of the luffing mechanism. 变幅 α is the luffing speed, φ is the angle of the linear trajectory, R is the horizontal distance of the hoisted object from the center of rotation, L is the boom length, θ is the luffing angle measured by the tilt meter in the pose detection unit, and ω is the luffing angle. 变幅 V is the angular velocity of the amplitude-changing mechanism. h修订 To correct the hoisting mechanism speed value based on the deviation of the hoisting height value measured by the pose detection unit from the actual hoisting height value, V h额定 The rated speed of the hoisting mechanism; Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected non-centripetal linear translation auxiliary operation mode, the PLC control unit automatically calculates the required operating angles of the slewing mechanism, the luffing mechanism, and the hoisting mechanism for the non-centripetal linear translation auxiliary operation. Based on the spatial trajectory of the non-centripetal linear translation operation, it calculates the required angular velocity setpoints for the slewing mechanism, the linear velocity setpoints for the luffing mechanism, and the speed setpoints for the hoisting mechanism during the non-centripetal linear translation auxiliary operation control process. Then, the PLC control unit controls the drive unit to complete the corresponding actions according to the calculated angular velocity setpoints for the slewing mechanism, the linear velocity setpoints for the luffing mechanism, and the speed setpoints for the hoisting mechanism, achieving a constant-height translational movement of the hoisted object from the starting position to the target object along any straight line direction.

6. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, When the auxiliary operation mode is fixed-posture movement, the PLC control unit controls the hook slewing mechanism to operate in opposite directions to match the speed of the slewing mechanism during the operation of the slewing mechanism, so as to maintain the posture of the hoisted object unchanged during the slewing process. The specific control method is as follows: The setpoint for the speed of the hook slewing mechanism is: V 吊钩 = -V 回转 ×N 吊钩 ÷N 回转 ; Among them, V 回转 N is the operating speed of the rotary mechanism. 吊钩 N is the numerical ratio of the hook's rotational speed to its angular velocity. 回转 This refers to the numerical ratio of the speed and angular velocity of the rotary mechanism; Based on the spatial coordinates of the target position set by the human-machine interface unit and the selected fixed-posture movement assisted operation mode, the PLC control unit automatically calculates the setpoint speed of the hook slewing mechanism required for the fixed-posture movement assisted operation. Then, the PLC control unit controls the drive unit to complete the corresponding action according to the calculated setpoint speed of the hook slewing mechanism, ensuring that the posture of the hoisted object remains unchanged during the slewing process.

7. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, When the auxiliary operation mode is multi-point obstacle avoidance movement, the PLC control unit automatically adds a path point between the starting position and the target position when there is an obstacle on the path of the hoisted object from the starting position to the target position, and sequentially selects spatial displacement, centripetal translation or non-centripetal linear translation auxiliary control actions to enable the hoisted object to automatically avoid obstacles during the hoisting process.

8. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, When the auxiliary operation mode is step-by-step movement, the PLC control unit controls the hoisting mechanism, luffing mechanism, slewing mechanism and hook slewing mechanism to perform speed control according to the step alignment distance value entered by the operator, so as to achieve short-distance precise alignment of the hoisted object.

9. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, The pose detection unit includes a laser scanner and a high-definition camera installed at the end of the boom, as well as a point cloud processing server and an image processing server installed in the PLC room. The laser scanner is used to collect point cloud data of the working area under the rotary crane and transmit it to the point cloud processing server. The point cloud processing server obtains real-time location data of the hoisted object and the working environment by performing calculations on the point cloud data. The high-definition camera is used to collect image data of the working area under the slewing crane and transmit it to the image processing server. The image processing server obtains the real-time posture data of the hoisted object by performing calculations on the image data.

10. The intelligent auxiliary control system for a fixed rotary crane according to claim 1, characterized in that, The PLC control unit also includes 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 in the security detection unit. The PLC module receives the detection signals collected by the DI module for anti-collision protection. The AI ​​module is used to collect detection data from the main hook weighing sensor, the auxiliary hook weighing sensor, and the anemometer in the security detection unit. The PLC module receives the detection data collected by the AI ​​module and is used for overload protection and wind protection. The PLC module receives detection data from the main lifting encoder, auxiliary lifting encoder, inclinometer, Gray busbar encoder, and hook slewing encoder in the pose detection unit via a switch, and uses this data to acquire the main lifting height, auxiliary lifting height, luffing angle, slewing angle, and main hook slewing angle.

Images