Crane system and method of controlling a crane system

Abstract

A crane system capable of positioning a suspended load to a target position while suppressing load sway is provided. The system includes a crane, a crane control unit, and a motor drive unit. The positioning control unit of the crane control unit includes: a recording unit that records a dataset containing the motor deceleration start time, the arrival position of the suspended load, and the motor deceleration time when load sway control is performed with a preset swing length; a drive parameter determination unit that, based on the dataset, determines the motor deceleration start time and stop time according to the actual swing length and the target position of the suspended load; and a drive signal output unit that outputs drive signals according to the deceleration start time and stop time. The motor control unit of the crane control unit includes: a speed command value generation unit that generates a target speed command value for controlling the motor according to the drive signal; and a load sway suppression control unit that generates a speed command value for suppressing the sway of the suspended load based on the target speed command value.

Description

Technical Field

[0001] This invention relates to a crane system for suspending and transporting loads and a control method for the crane system. Background Technology

[0002] In recent years, with the aging of skilled crane operators and the resulting manpower shortage due to the increase in the number of cranes, there has been an increase in inexperienced operators taking over crane operation. For these inexperienced operators, stopping the swaying of the load (load sway) is difficult, and the time required to position the load at the target location also increases. Therefore, there is a need for a technology that can safely and quickly suppress load sway and position the load at the target location.

[0003] As an example of this technology, a control method for a bridge crane is known in Patent Document 1. The abstract of this document describes the subject as "simultaneously improving anti-sway control and positioning control, while also enhancing anti-sway accuracy and positioning accuracy." As a solution, it describes "creating a basic speed pattern for the moving body based on from / to data and sling length. After the winch starts, the initial sway of the spreader is measured, and the acceleration is corrected to a value corresponding to the initial sway for accelerated operation. During constant speed operation, the transition sway of the spreader is measured, and the deceleration pattern and deceleration point are corrected based on the control data during transition sway and acceleration. At the deceleration point, the system transitions to deceleration operation, where the residual sway of the spreader is measured, and the deceleration is corrected to a value corresponding to the residual sway. The system transitions to low-speed operation at a creeping speed, where the stop point is corrected based on the control data during deceleration, and a stop command is output at the stop point."

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2000-289978 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] In Patent Document 1, a basic speed pattern is created based on the starting position (from data), the target position (to data), and the sling length. During the movement of the moving body, the basic speed pattern is corrected according to the measured swing of the sling, thereby suppressing the swing of the sling and positioning the moving body at the target position.

[0009] However, as described in paragraph 0007 of this document, "a traveling laser rangefinder 19 for measuring the current position of the trolley 2, a traversing laser rangefinder 20 for measuring the current position of the crane 3, and a TV camera 21 for detecting the swing angle of the spreader 6 are installed on the side of the bridge crane," as described in paragraph 0009, "a swing angle detection unit 44 for detecting the swing angle of the spreader 6 based on the signal from the TV camera 21," and as described in paragraph 0012, "next, the hoisting begins (step S7), and the initial swing of the spreader 6 is measured using the TV camera 21 (step S8)," in order to realize the technology of this document, a TV camera (swing measurement sensor) is needed to measure the swing (initial swing, transition swing, residual swing), which increases the price and complicates the crane system due to the use of a TV camera.

[0010] Furthermore, in the technology of Patent Document 1, the motion characteristics such as the time from the start of deceleration to the stop and the distance traveled change according to the change in the speed mode during the operation, so there is also the problem that the crane operator has difficulty predicting its behavior.

[0011] In view of these problems, the purpose of the present invention is to provide a crane system and crane control method that can maintain the characteristics of previous load swing suppression control without the need for additional swing measurement sensors, and can accurately achieve the positioning control of the hoisted object.

[0012] Technical means for solving problems

[0013] To address the aforementioned problems, the present invention provides an example of a crane system, comprising: a crane including a winch device powered by an electric motor that moves a load vertically by lowering a sling and a horizontal movement device powered by an electric motor that moves the load horizontally; a crane control device that outputs a speed command value corresponding to the target position of the load; and an electric motor drive device that supplies electrical power to the electric motor corresponding to the speed command value. The positioning control unit of the crane control device includes a recording unit that records the deceleration of the electric motor when performing load swing control with a preset swing length. The crane control device includes: a dataset of the start time, the arrival position of the hoisted object, and the deceleration time of the motor; a drive parameter determination unit that, based on the dataset, determines the start and stop times of the motor's deceleration according to the actual swing length and the target position of the hoisted object; and a drive signal output unit that outputs drive signals according to the start and stop times of deceleration. The motor control unit of the crane control device includes: a speed command value generation unit that generates a target speed command value for controlling the motor according to the drive signal; and a load swing suppression control unit that generates a speed command value for suppressing the swing of the hoisted object based on the target speed command value.

[0014] Invention Effects

[0015] According to the crane system and crane control method of the present invention, the characteristics of the previous load swing suppression control can be maintained without the need for additional load swing measurement sensors, and the positioning control of the hoisted object can be accurately realized. Attached Figure Description

[0016] Figure 1 This is a structural diagram showing the general structure of a bridge crane.

[0017] Figure 2 This is a block diagram showing the structure of the crane system in Embodiment 1.

[0018] Figure 3A This is a diagram illustrating the principle of positioning control in Embodiment 1.

[0019] Figure 3B This is a diagram illustrating the principle of positioning control in Embodiment 1.

[0020] Figure 3C This is a diagram illustrating the principle of positioning control in Embodiment 1.

[0021] Figure 3D This is a diagram illustrating the principle of positioning control in Embodiment 1.

[0022] Figure 4 This is a diagram showing the structure of a crane control device with positioning control installed in Embodiment 1.

[0023] Figure 5 This is a diagram illustrating the operation of the speed command value generation unit.

[0024] Figure 6 This is a graph illustrating the time-varying speed of the trolley and the time-varying position of the suspended object in Embodiment 2.

[0025] Figure 7 This is a diagram illustrating the structure of the positioning control unit in Embodiment 3.

[0026] Figure 8A This is a diagram illustrating the principle of positioning control in Example 4.

[0027] Figure 8B This is a diagram illustrating the principle of positioning control in Example 4.

[0028] Figure 8C This is a diagram illustrating the principle of positioning control in Example 4.

[0029] Figure 9 This is a conceptual diagram of the crane system in Example 5.

[0030] Figure 10 This is a diagram showing the structure of a crane control device with positioning control installed in Embodiment 6. Detailed Implementation

[0031] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The embodiments are illustrative of the present invention, and omissions and simplifications have been appropriately made for clarity of explanation. The present invention can also be implemented in various other ways. Unless otherwise specified, each constituent element may be single or multiple. For ease of understanding, the positions, sizes, shapes, extents, etc., of the constituent elements shown in the accompanying drawings sometimes do not represent actual positions, sizes, shapes, extents, etc. Therefore, the present invention is not necessarily limited to the positions, sizes, shapes, extents, etc., disclosed in the accompanying drawings.

[0032] As examples of various types of information, they are sometimes described using expressions such as "table," "list," and "queue," but various types of information can also be expressed using data structures other than these. For example, various types of information such as "XX table," "XX list," and "XX queue" can also be set as "XX information."

[0033] When multiple constituent elements have the same or identical function, different subscripts are sometimes used to describe the same reference numerals. Conversely, when it is not necessary to distinguish these multiple constituent elements, the subscripts are sometimes omitted in the description.

[0034] In the embodiments, the processing performed by executing the program is sometimes described. Here, the computer executes the program through a processor (e.g., CPU, GPU), using storage resources (e.g., memory), interface devices (e.g., communication ports), etc., to perform processing determined by the program. Therefore, the processor can also be considered as the subject of the processing performed by executing the program. Similarly, the subject of the processing performed by executing the program can also be a controller, device, system, computer, or node having a processor. The subject of the processing performed by executing the program can be any arithmetic unit, or it can include dedicated circuitry for performing specific processing. Here, dedicated circuitry includes, for example, FPGA (Field Programmable Gate Array), ASIC (Application Specific Integrated Circuit), CPLD (Complex Programmable Logic Device), etc.

[0035] The program can also be installed onto the computer from a program source. A program source can be, for example, a program distribution server or a computer-readable storage medium. When the program source is a program distribution server, the program distribution server includes a processor and storage resources for storing the programs to be distributed. The processor of the program distribution server can also distribute the programs to other computers. Furthermore, in embodiments, two or more programs can be implemented as a single program, or a single program can be implemented as two or more programs.

[0036] Here, the invention is effective for all cranes capable of moving loads horizontally, and is also applicable to cranes that move loads laterally and travel by means of a trolley and main beam (e.g., bridge cranes), as well as cranes that only move loads laterally or travel (e.g., unloaders). That is, the term "crane" as used below includes all types of cranes capable of moving loads horizontally.

[0037] Furthermore, goods transported by cranes (lifted loads) are suspended by slings, chains, etc. However, in this invention, any lifting device capable of suspending goods is acceptable, without limitation; the material, shape, etc., can also be of any type. Therefore, as mentioned above, the term "sling" is used as a general term for lifting devices used to suspend goods. That is, "sling" includes not only so-called slings, but also chains, belts, wires, cables, ropes, cords, etc.

[0038] [Example 1]

[0039] First, use Figures 1 to 5 The crane system 100 according to Embodiment 1 of the present invention will be described below. Furthermore, in each figure, the same reference numerals are used to label the same equipment (device, component), and descriptions of equipment that have already appeared are sometimes omitted in the following description.

[0040] Figure 1 This is a schematic structural diagram showing a typical bridge crane (hereinafter referred to as "crane 1"). As described above, the crane in the crane system 100 of the present invention is not limited to a bridge crane.

[0041] The crane 1 illustrated here includes: a traveling track 2 installed along the side walls of a building such as a factory (not shown); a main beam 3 that moves along the upper surface of the traveling track 2; and a trolley 4 that moves along the lower surface of the main beam 3. Wheels (not shown) driven by electric motors (referred to as traveling motor and traversing motor, respectively) are installed on the main beam 3 and the trolley 4, allowing the main beam 3 and the trolley 4 to move horizontally via these wheels. A winch 5 is installed at the lower part of the trolley 4. The winch 5 consists of a winch motor and a drum that rotates and winds a sling 6 via the winch motor. By using the winch 5 to winch or lower the sling 6, the hook 7 at the front end of the sling 6 is raised or lowered. A load 9 is suspended directly from the hook 7 or via a lifting cable 8, and the load 9 rises or falls with the raising or lowering of the hook 7.

[0042] That is, the crane 1 in this embodiment can move the load 9 horizontally by moving the main beam 3 horizontally (traveling) and the trolley 4 horizontally (traversing), and can raise and lower the load 9 vertically (up and down) by using the winch device 5. In this crane 1, both the trolley 4 and the main beam 3 are equivalent to "horizontal moving devices", but either the trolley 4 or the main beam 3 can be designated as the "horizontal moving device".

[0043] Figure 2 This is a block diagram illustrating the structure of the crane system 100 of this embodiment. Furthermore, for the sake of simplicity, only structures related to the traversal of the trolley 4 and the lifting of the hoisting device 5 are shown in this figure; diagrams of structures related only to the travel of the main beam 3 (travel track 2, travel motor drive device, etc.) are omitted. Additionally, diagrams of drive units such as motors are also omitted.

[0044] As shown here, the crane system 100 of this embodiment is a system that, in addition to the crane 1 described above, also includes a crane control device 10, an input / output device group 20, and a motor drive device group 30. The details of each device will be described below.

[0045] (Crane control device 10)

[0046] The crane control device 10 in this embodiment is, for example, a general-purpose computer, including: a microprocessor unit (MPU) 101 that performs control calculations using built-in programs and data; a memory 102 such as an HDD or RAM that records the aforementioned programs and data; and an input / output control unit 103 for outputting external data and signal inputs, and signals processed by the MPU 101. Furthermore, the MPU 101, memory 102, and input / output control unit 103 are connected via a bus 104 for transmitting and receiving signals and data. By executing a predetermined program, the crane control device 10 realizes the functions of the positioning control unit 11, motor control unit 12, etc., described later.

[0047] (Input / output device group 20)

[0048] The input / output device group 20 in this embodiment consists of a controller 21, a display device 22, and an input device 23.

[0049] The controller 21 is an instrument operated by the operator of the crane 1, and is equipped with operation buttons 21a corresponding to the forward, backward, right, left, upward, and downward directions of the load 9. Therefore, for example, if the operator presses the forward button, the crane control device 10 and the motor drive unit 30 can appropriately drive the motor of the crane 1, causing the load 9 to move forward. Furthermore, the connection between the controller 21 and the crane control device 10 can be wired or wireless.

[0050] The display device 22 is a display that shows the status of the crane 1, etc. Alternatively, the display device 22 and the controller 21 can be mounted in the same housing.

[0051] The input device 23 is used by the operator to input the target position of the hoisted object 9, the swing length L (described later), etc. When the operator inputs the target position of the hoisted object 9, the coordinates of the hoisted object in each direction of lateral movement, travel, and hoisting, or the amount of movement from the current position, are numerically input through the input device 23. Alternatively, the coordinates can be pre-registered and retrieved. Alternatively, a map can be displayed on the input device 23, and the target position can be specified on the map. Furthermore, the coordinates of the target position and the amount of movement from the current position can be obtained from an external system.

[0052] (Motor drive unit group 30)

[0053] The electric motor drive unit group 30 in this embodiment consists of a horizontal electric motor drive unit 31, a hoisting electric motor drive unit 32, and a travel electric motor drive unit (not shown).

[0054] The traverse motor drive unit 31 is a device that supplies electrical power corresponding to the trolley speed command value from the crane control unit 10 to control the traverse motor of the trolley 4. Furthermore, the winch motor drive unit 32 is a device that supplies electrical power corresponding to the winch speed command value from the crane control unit 10 to control the winch motor of the winch device 5. Also, the travel motor drive unit (not shown) is a device that controls the travel motor of the main beam 3 according to the main beam speed command value from the crane control unit 10. Furthermore, although in Figure 2 The specific structure is not shown, but each motor drive unit is a device with an inverter circuit and the like added to a general-purpose computer with the same structure as the crane control unit 10. Alternatively, each motor drive unit can be mounted in the same housing as the crane control unit 10.

[0055] (The principle of positioning control)

[0056] Next, use Figures 3A to 3D The principle of the positioning control of the present invention will be explained. Here, taking the case where load swing suppression control is performed while the suspended object 9 is positioned laterally to a target position set in the lateral direction as an example, the details of the positioning control process will be explained. In addition, the positioning control process of the present invention consists of the following four processes, which are the first and second processes as data collection processes before actual work, and the third and fourth processes as processes during actual work.

[0057] ((First Processing S1))

[0058] The first process S1 involves acquiring time response data of the trolley speed, the load position, and the load swaying, based on the time response data obtained when the crane control device 10 sends a predetermined trolley speed command value to the traverse motor drive device 31 to drive the traverse motor, for each swing length L. Therefore, in this first process S1, while performing load sway suppression control with multiple preset swing length settings, the acceleration of the traverse motor of the trolley 4 is initiated, and the traverse motor is decelerated from a specified deceleration start time T0, sequentially acquiring the traverse position of the load until the load 9 stops. Furthermore, the data acquisition for this process can be performed using a real machine or through simulation. Additionally, the deceleration start time T0 can be specified within the time range for long-distance transport starting from the micro-motion operation.

[0059] Here, the pendulum length L is the distance from the swing center of the sling 6 to the center of gravity of the load 9. Alternatively, the distance from the hook 7 to the center of gravity of the load 9 can be set with a certain offset value, and the pendulum length L can be defined as the value obtained by adding the offset value to the distance from the swing center of the sling 6 to the hook 7 (measured by an encoder mounted on the winch motor), i.e., the sling length. Furthermore, the pendulum length L can also be defined as the value obtained by adding the sling length and the equivalent center of gravity distance without any overlap. This pendulum length L is specified within the range of conditions where the load is suspended at the lowest position and conditions where the load is suspended at the highest position.

[0060] use Figure 3A An example of data obtained in the first process S1 is explained. The data D0 illustrated in the figure represents a set of data measuring (a) the trolley speed, (b) the position of the load, and (c) the time variation of the load swing when the pendulum length L is set to L0 (e.g., 1m) and three different trolley speed command values ​​V0, V1, and V2 at the deceleration start time T0 are given to the horizontal motor drive device 31. In addition, as shown in the curve of (a) trolley speed, since load swing suppression control is applied to the solid line "trolley speed command value V", the load 9 can be transported at a monotonic speed shown by the dashed line "target speed of the load" by driving the horizontal motor based on this command value.

[0061] Similarly, data D1 is the set of measurement data when the pendulum length L is set to L1 (e.g., 1.5m), and data D2 is the set of measurement data when the pendulum length L is set to L2 (e.g., 2m). Additionally, in Figure 3A In this example, for the sake of simplicity, we show an example of obtaining 9 data sets that combine 3 pendulum lengths L and 3 trolley speed command values ​​V, but more data sets can be obtained in this step.

[0062] (Second Processing S2)

[0063] In the second process S2, based on the data D obtained in the first process S1, the relationship between the stopping position of the hoisted object 9 (the hoisted object's arrival position X) relative to the deceleration start time T0 and the relationship between the time required from the start of deceleration by the horizontal motor to the stop (deceleration time Δt) is recorded as a dataset DS for each pendulum length L. Furthermore, the pendulum length setting, deceleration start time T0, hoisted object arrival position X, and deceleration time Δt recorded as dataset DS are discrete numerical data.

[0064] use Figure 3BThis section explains an example of the datasets obtained in the second process S2. The dataset DS0 illustrated in this figure represents the relationship between the deceleration start time T0 and the arrival position X of the suspended load when the pendulum length L is L0, and the relationship between the deceleration start time T0 and the deceleration time Δt. Similarly, dataset DS1 represents the dataset when the pendulum length L is L1, and dataset DS2 represents the dataset when the pendulum length L is L2. Furthermore, in... Figure 3B The example shows datasets DS0, DS1, and DS2 corresponding to pendulum lengths L0, L1, and L2, but this is because... Figure 3A Based on the data set, the number of datasets obtained in this step is not limited to 3.

[0065] (Third Processing S3)

[0066] In the third process S3, based on the multiple datasets DS obtained in the second process S2, it is decided to actually transport the hoisted object 9 to the target location X. T The deceleration start time T0 and the predicted deceleration completion time (deceleration time Δt) of the horizontal motor are calculated. Furthermore, the pendulum length L during actual operation will be referred to as the actual pendulum length L. A .

[0067] The pendulum length L and the position X of the suspended load recorded in the dataset DS obtained in the second process S2 are discrete numerical data, and therefore may not be consistent with the actual pendulum length L. A The location X of the hoisted object is consistent with the location X. Therefore, by performing interpolation processing in the following order, the relationship with any L is determined. A X T The corresponding deceleration start time T0 and deceleration time Δt. Alternatively, a method can be used that utilizes a dataset close to the acquired dataset without interpolation. Hereinafter, the operator will input L using input device 23. A (L1 < L) A <L2) and X T (X1 < X) T The explanation will be based on <X2). Additionally, the pendulum length L processed in the input device 23... A It is obtained by adding the offset value selected by the operator to the sling length measured by the encoder.

[0068] (1) First, extract the actual pendulum length L during transport from the dataset DS recorded in the second process S2. A The dataset DS1 and DS2 contains the lengths L1 and L2 of the pendulum before and after the pendulum.

[0069] (2) Next, extract the target position X from the obtained position X of the hoisted object of DS1. TThe arrival positions of the loads at X1 and X2, and the starting times of deceleration of the motors corresponding to X2 are T0(L1, X1) and T0(L1, X2).

[0070] (3) The extracted deceleration start times T0(L1, X1) and T0(L1, X2) are interpolated, and the pendulum length L1 is calculated using the following (Equation 1), which is relative to the arbitrary target position X. T The corresponding deceleration start time T0(L1, X) T ) (reference Figure 3C (Middle layer upper curve).

[0071] [Formula 1]

[0072]

[0073] (4) Similar to (2) above, extract the target position X of the hoisted object 9 from the obtained position of the hoisted object DS2. T The deceleration start times T0(L2,X1) and T0(L2,X2) of the motors corresponding to the arrival positions X1 and X2 of the suspended load before and after are determined. Then, similarly to (3) above, the extracted deceleration start times T0(L2,X1) and T0(L2,X2) are interpolated. The pendulum length L2 is calculated using the following formula (2) and the result is relative to any target position X. T The corresponding deceleration start time T0(L2, X) T ) (reference Figure 3C (The upper curve of the lower layer).

[0074] [Formula 2]

[0075]

[0076] (5) The deceleration start time T0 (L1, X) when the pendulum length L1 is obtained by (Equation 1) T ) and the deceleration start time T0(L2, X) when the pendulum length L2 is obtained by (Equation 2). T Interpolation is performed, and the result is calculated using Equation 3 below, along with any actual pendulum length L. A Target location X T The corresponding deceleration start time T0 (L) of the horizontal motor A X T ).

[0077] [Formula 3]

[0078]

[0079] (6) The deceleration time Δt is also compared with the deceleration start time T0 (L) in (2) to (5). A XT The same calculation process is used to determine the actual pendulum length L. A Target location X T The corresponding deceleration time Δt (L) of the horizontal motor A X T ).

[0080] (S4)

[0081] In the fourth process S4, the deceleration start time T0 (L) determined in the third process S3 is used. A X T ) and deceleration time Δt (L A X T The calculation formula controls the On / Off (on / off) of the drive signal of the horizontal motor. Specifically, if the time from when the drive signal is On and the horizontal motor starts to operate reaches the deceleration start time T0 (L) determined in the third process S3, the calculation formula is used to control the On / Off (on / off) of the drive signal of the horizontal motor. A X T The time calculated by the formula is then set to Off. Furthermore, if the start time of the horizontal motor reaches the stop time T1 (L... A X T ) = T0(L A X T )+Δt(L A X T Then the drive of the horizontal motor ends. By determining the deceleration start time T0 and deceleration time Δt of each motor as described above, the load can be transported to the target position X while taking into account the characteristics of load swing suppression. T .

[0082] Figure 3D This is a flowchart illustrating the details of the third process S3 and the fourth process S4.

[0083] In step S31, the positioning control unit 11 of the crane control device 10 obtains the actual swing length L input by the operator via the input device 23. A and target location X T .

[0084] In step S32, the positioning control unit 11 calculates the actual pendulum length L through the third process S3 described above. A and target location X T The corresponding deceleration start time T0 (L) A X T ) and deceleration time Δt (L A X T ), and then use them to calculate the stopping time T1 (L A X T）.

[0085] In step S41, the positioning control unit 11 sets the motor drive signal to On.

[0086] In step S42, the positioning control unit 11 determines whether the elapsed time from when the drive signal of the motor is turned on is the deceleration start time T0 (L). A X T Then, if the requirements are met, proceed to step S45; otherwise, repeat this step.

[0087] In step S43, the positioning control unit 11 sets the drive signal of the motor to Off.

[0088] In step S44, the positioning control unit 11 determines whether the elapsed time from when the drive signal of the motor is turned on is the stopping time T1 (L). A X T This determines whether the suspended load suppresses load swing and reaches the target position X. T Then, if the requirements are met, the process ends and the movement to the next target position begins. If the requirements are not met, this step is repeated. Thus, by waiting until the stopping time T1 (L... A X T This enables the suppression and positioning of load sway at the target location, and also prevents the accumulation of load sway and positioning errors during movement to the next target location.

[0089] (Specific structure of crane control device 10)

[0090] Figure 4 This indicates that it has been installed. Figures 3A to 3D A functional block diagram of the specific structure of the crane control device 10 for positioning control is provided. The following describes in detail the positioning control unit 11 and the motor control unit 12 of the crane control device 10. Furthermore, in... Figure 4 In this description, the positioning control unit 11 and the motor control unit 12 are installed in the same housing, but they can also be installed in different housings. Of course, when they are installed in different housings, the drive signals are exchanged between the housings.

[0091] (Positioning Control Unit 11)

[0092] Positioning control unit 11 is based on the actual swing length L input from input device 23 A and target location X T The functional unit for calculating the motor drive signal has a drive parameter determination unit 11a, a drive signal output unit 11b, and a recording unit 11c.

[0093] In the recording unit 11c, a dataset DS, obtained in the first process S1 and the second process S2 described above, is recorded according to each prescribed pendulum length L. This dataset includes the motor deceleration start time T0, the load arrival position X, and the deceleration time Δt. Furthermore, the recording unit 11c can be the same as the memory 102 mounted on the crane control device 10, or it can be installed in a different housing.

[0094] In the drive parameter determination unit 11a, based on the dataset DS recorded in the recording unit 11c, the aforementioned third process S3 is performed, thereby determining the target position X. T And the actual pendulum length L A The deceleration start time T0 and deceleration time Δt of the motor are determined. In addition, the drive parameter determination unit 11a can determine the deceleration start time T0 and deceleration time Δt of the travel motor of the main beam 3, the traverse motor of the trolley 4, and the hoisting motor of the hoisting device 5, respectively.

[0095] The drive signal output unit 11b executes the fourth processing S4 described above, controlling the On / Off output of the motor drive signal based on the deceleration start time T0 and the stop time T1 = T0 + Δt. Furthermore, the drive signal output unit 11b can control the On / Off output of the motor drive signals for the main beam 3's travel motor, the trolley 4's traverse motor, and the hoisting motor of the hoisting device 5, respectively.

[0096] (Electric motor control unit 12)

[0097] The motor control unit 12 is a functional unit that calculates the speed command value V of the motor based on the motor drive signal, and includes a speed command value generation unit 12a and a load swing suppression control unit 12b.

[0098] The speed command value generation unit 12a calculates the speed command value V of the hoisted target based on the motor drive signal input from the positioning control unit 11. tgt The load swing suppression control unit 12b outputs the output. Additionally, the speed command value generation unit 12a can calculate the target speed command value V for the main beam 3's travel motor, the trolley 4's traverse motor, and the hoisting device 5's hoisting motor. tgt .

[0099] Figure 5 This diagram illustrates the operation of the speed command value generation unit 12a. As shown here, if the motor drive signal changes from Off to On, the speed command value V of the hoisted target is increased according to a pre-specified acceleration. tgt Accelerate to rated speed V max Additionally, when the motor drive signal changes from On to Off, the target speed command value V of the hoisted object is increased according to the specified deceleration. tgt Decelerate to 0.

[0100] The load sway suppression control unit 12b is based on the target speed command value V of the suspended object input from the speed command value generation unit 12a. tgt The system calculates the speed command value V used to suppress load sway and outputs it to the motor drive unit 30. Furthermore, the load sway suppression control unit 12b can calculate the speed command value V for the main beam 3's travel motor, the trolley 4's traverse motor, and the hoisting motor of the hoisting device 5. Figure 3A The speed command value V is illustrated by the solid line in the curve of the speed of the (a) trolley at each level.

[0101] The load sway suppression control unit 12b can use a load sway suppression control device, such as the one shown in Japanese Patent Application Publication No. 2022-15495, which does not require feedback on the sway amount of the suspended load or the sling angle. The load sway suppression control device only needs to have a deceleration start time T0 and a deceleration time Δt relative to the actual sway length L. A Target location X T The characteristic that can be determined with high reproducibility is unique, or it can be a structure other than that shown in Japanese Patent Application Publication No. 2022-15495. Furthermore, a structure that adds a correction amount for the swing of the suspended object and the swing angle of the sling to the target speed of the suspended object can also be adopted.

[0102] (Effect of this embodiment)

[0103] The positioning control unit 11 of this embodiment is characterized in that, when positioning the load at the target position, it automatically generates an appropriate motor drive signal that mimics the On / Off operation of the control button 21a of the controller 21 operated by a skilled operator, and outputs it to the motor control unit 12. Therefore, as long as the motor control unit 12 has the function of receiving the On / Off signal of the controller 21 to realize load swing suppression control, it can cooperate with the positioning control unit 11 of this embodiment without any changes to its structure or control parameters. In addition, the load swing suppression characteristics of the motor control unit 12 will not change due to the positioning control of the positioning control unit 11.

[0104] As described above, with the crane system of this embodiment, even inexperienced operators can position the load at the desired target location X while suppressing load sway. T .

[0105] [Example 2]

[0106] Next, the crane system 100 of Embodiment 2 of the present invention will be described. Furthermore, repeated descriptions of points common to Embodiment 1 will be omitted. In this embodiment, based on the recorded dataset DS, the calculation of the actual swing length L is derived. A and target location X TAn approximate formula is used to determine the deceleration start time T0 and the deceleration time Δt, and the parameters are determined by this approximation.

[0107] Figure 6 This is a graph illustrating the time-varying speed of (a) the trolley and the time-varying position of (b) the load when the horizontal motor is activated. If we focus on the trolley speed, then... Figure 6 The period is divided into the acceleration of the car from 0 to the rated speed V. max Acceleration range I, the car speed maintains the rated speed V max The constant speed range II, the speed of the trolley from the rated speed V max The three intervals are: deceleration interval III, which decelerates to 0.

[0108] The distance traveled in acceleration zone I, i.e., the distance Da required for acceleration, and the distance traveled in deceleration zone III, i.e., the distance Dd required for deceleration, are determined by the actual pendulum length L. A Rated speed V max The characteristics of acceleration, deceleration, and load sway suppression control are determined by these factors. Therefore, from the starting position to the target position X... T When the distance required for acceleration and deceleration is greater than or equal to the distance D = Da + Dd, the position of the suspended load is adjusted by adjusting the distance in constant speed range II. The deceleration time Δt at this point becomes determined by the actual pendulum length L. A The constant value t determined d Additionally, at the target location X T If the distance is shorter than the distance D required for acceleration and deceleration, the rated speed V can be reduced. max And shorten Da and Dd to adjust the arrival position.

[0109] Based on the above explanation, X T The deceleration start time T0 and deceleration time Δt when ≥D can be approximated as follows.

[0110] T0 = ​​(X T -D(L A )) / V max

[0111] Δt=t d (L) A )

[0112] Additionally, D(L) A ), t d (L) A (L) is the actual pendulum length. A The function, D(L) A ) can use L A The polynomial approximation.

[0113] D=Σ(K i *L Ai (i=0,1,...,n)

[0114] The coefficients K of the polynomial i And the number of times n, t d (L) can be determined by least squares or other methods based on a pre-recorded dataset DS.

[0115] Additionally, X T When the deceleration starts at time T0 and the deceleration time Δt is less than D, X can be used to determine the starting time of deceleration. T The polynomial approximation.

[0116] T0=Σ(P i (L) A )*X T i (i=0,1,...,m)

[0117] Δt=Σ(Q i (L) A )*X T i (i=0,1,...,l)

[0118] Here, the coefficients P of the polynomial i (L) A Q i (L) A ) is L A The function, P i Q i The order m and l can be determined by the least squares method or other methods based on the recorded dataset DS.

[0119] As described above, if the deceleration start time T0 and deceleration time Δt are determined using approximations, it is not necessary to use the entire dataset DS obtained in advance during execution to determine the parameters. The approximation parameters can be loaded into memory, reducing the memory usage. Furthermore, using approximations allows for more precise determination of the drive parameters compared to interpolation.

[0120] [Example 3]

[0121] Next, the crane system of Embodiment 3 of the present invention will be described. Furthermore, repeated descriptions of points common to the embodiments described above will be omitted. In this embodiment, a neural network learned based on a pre-recorded dataset DS is used to adjust the actual swing length L. A Target location X T Determine the deceleration start time T0 and the deceleration time Δt.

[0122] Figure 7This diagram illustrates a structural example of the positioning control unit 11 in this embodiment. The positioning control unit 11 in this embodiment includes: a drive parameter determination unit 11a, which uses a neural network to determine the deceleration start time T0 and deceleration time Δt based on the pendulum length L and the target position X; a drive signal output unit 11b, which outputs a drive signal based on the determined deceleration start time T0 and deceleration time Δt; a recording unit 11c, which records the dataset DS used for learning and the learning result R; and a learning unit 11d, which learns the coefficients of the neural network.

[0123] In the driving parameter determination section 11a, a neural network is used to perform the following calculations in each layer.

[0124] u=Wx+b

[0125] Here, x is the input vector of each layer, W is the coefficient matrix representing the weights, and b is the vector representing the bias. W and b are determined by optimization learning based on the dataset DS recorded on the recording device, using the backpropagation method. Furthermore, the learned W and b are recorded as the learning result R in the recording unit 11c and loaded from the recording unit 11c before the neural network operation.

[0126] By using neural networks as described above, even when the approximation of the deceleration start time T0 and deceleration time Δt based on the pendulum length and target position cannot achieve sufficient accuracy, the driving parameters can be determined with a simple structure.

[0127] [Example 4]

[0128] Next, the crane system of Embodiment 4 of the present invention will be described. Furthermore, repeated descriptions of points common to the above embodiments will be omitted.

[0129] In load sway suppression, the load on the hoisted object 9 changes, thereby altering its characteristics. This is because the inertial force generated by acceleration and deceleration based on horizontal movement varies according to the load on the hoisted object 9, and the traverse motor and travel motor must be used to counteract this torque variation of inertial force. Therefore, in this embodiment, the load information of the hoisted object 9 is included in the dataset DS.

[0130] Figures 8A to 8C This diagram illustrates the positioning control process when load information of hoisted object 9 is appended to the dataset DS. It is essentially the same as... Figures 3A-3C correspond.

[0131] Figure 8AThis is a diagram corresponding to the first process S1 in this embodiment. In the first process S1 of embodiment 1, under the premise that the load of the suspended object 9 is constant, while changing the pendulum length L, the following parameters are measured respectively: (a) trolley speed, (b) position of the suspended object, and (c) load swing (refer to...). Figure 3A Data D0 to D2). In contrast, in this embodiment, while changing the load of the suspended object 9, the same measurements as the first process S1 of Embodiment 1 are performed on each load. As a result, according to the first process S1 of this embodiment, it is possible to obtain data sets measured under the condition of a suspended object 9 with a load M0, data sets measured under the condition of a suspended object 9 with a load M1, and data sets measured under the condition of a suspended object 9 with a load M2. In addition, Figure 8A The example shown illustrates data sets measured for three types of loads 9: M0, M1, and M2. However, the load settings can be appropriately set within the range of the minimum to maximum allowable load values. Furthermore, this data can be obtained using a live machine or through simulation.

[0132] Figure 8B This is a diagram corresponding to the second process S2 in this embodiment. In the second process S2 of Embodiment 1, a set of datasets DS is recorded under the premise that the load of the hoisting object 9 is constant. However, in this embodiment, a set of datasets DS corresponding to the number of types of hoisting object loads obtained in the first process S1 is recorded. Therefore, as Figure 8A As shown, if the data sets are obtained for the three types of loads 9, namely loads M0, M1, and M2, then the data set DS corresponding to load M0 is obtained from the data set corresponding to load M0, the data set DS corresponding to load M1 is obtained from the data set corresponding to load M1, and the data set DS corresponding to load M2 is obtained from the data set corresponding to load M2.

[0133] Figure 8C This diagram corresponds to the third process S3 in this embodiment. In the third process S3 of Embodiment 1, under the premise that the load of the suspended object 9 is constant, the actual pendulum length L is determined. A Target location X T The corresponding deceleration start time T0 and deceleration time Δt, but in the third process S3 of this embodiment, it is determined that the actual pendulum length L is not the same. A Load M, target position X TThe corresponding deceleration start time T0 and deceleration time Δt. This decision can be made by interpolation based on the dataset DS, as in Example 1; or by using an approximate formula to obtain the deceleration start time T0 and deceleration time Δt based on L, M, and X, as in Example 2; or by using a neural network learned based on a pre-acquired dataset DS, as in Example 3.

[0134] In this embodiment, it is also in accordance with Figure 3D The flowchart executes the third process S3 and the fourth process S4. That is, the positioning control unit 11 obtains the actual pendulum length L in step S31. A and target location X T In step S32, the actual pendulum length L is calculated. A Actual load M and target position X T The corresponding deceleration start time T0 and deceleration time Δt are used to calculate the stopping time T1. Then, in step S41, the motor drive signal is set to On; in step S42, it is determined whether the elapsed time has reached the deceleration start time T0; and in step S43, the motor drive signal is set to Off. Then, in step S44, it is determined whether the elapsed time has reached the stopping time T1; if the condition is met, the process ends.

[0135] As mentioned above, the characteristic changes in load sway suppression control caused by the load of the suspended object can be taken into account, thereby improving load sway suppression performance and positioning accuracy.

[0136] [Example 5]

[0137] Next, the crane system of Embodiment 5 of the present invention will be described. Furthermore, repeated descriptions of points common to the above embodiments will be omitted.

[0138] Figure 9 This is a conceptual diagram illustrating the structure of the crane system 100 of this embodiment. The dataset DS used in this invention is universal among cranes of the same type 1. Therefore, in the crane system 100 of this embodiment, multiple crane control devices 10 controlling cranes of the same type 1 can be communicatively connected via a cloud server, the datasets obtained by each crane control device 10 can be aggregated to the cloud server, and the parameters required for controlling the crane 1 can be recorded in the recording unit 11c of each crane control device 10.

[0139] For example, in Figure 9In this system, crane control device 10A, which controls crane 1A, and crane control device 10B, which controls crane 1B, are communicatively connected to a cloud server. The datasets acquired by both crane control device 10A and crane control device 10B are recorded in the recording unit of the cloud server. Therefore, compared to using a single crane control device 10, multiple datasets can be acquired more efficiently.

[0140] In addition, Figure 9 In the crane control device 10A, the recording unit 11c records the parameters required for controlling the crane 1A, which are calculated by referring to the dataset of the cloud server. In the crane control device 10B, the recording unit 11c records the parameters required for controlling the crane 1B, which are calculated by referring to the dataset of the cloud server.

[0141] In particular, as in Examples 2 and 3, when using an approximation and a neural network to obtain the deceleration start time T0 and deceleration time Δt, by also mounting the learning unit 11d, which performs the identification of approximation parameters and the learning of the neural network, on a cloud server, the computational load on the local crane control device 10 can be reduced, and higher accuracy learning results can be easily obtained.

[0142] By adopting this structure, the cloud server can collect a large amount of dataset DS of the same model, effectively utilize the parameters of the dataset DS for parameter identification and learning, and provide the crane with parameters for more accurate load sway suppression and positioning.

[0143] [Example 6]

[0144] Next, the crane system of Embodiment 6 of the present invention will be described. Furthermore, repeated descriptions of points common to the above embodiments will be omitted.

[0145] Figure 10 This diagram illustrates the structure of a crane using the positioning control unit 11 of the present invention. An input / output device group 20 is connected to the crane control device 10. By turning on / off the operation buttons 21a installed on the input / output device group 20 corresponding to the movement directions of the load (front, rear, right, left, above, and below), the drive signal of the motor corresponding to the button is input to the crane control device 10. Therefore, by setting the specification of the drive signal output from the positioning control unit 11 to the same specification as the drive signal from the input / output device group 20, the positioning control unit 11 can be connected to the crane control device 10.

[0146] By adopting such a structure, positioning functions can be added to cranes that do not have positioning control functions.

[0147] Furthermore, the present invention is not limited to the above-described embodiments and includes various modifications. The embodiments described above are examples provided for easy understanding and illustration of the present invention, and are not limited to having all the described structures. Additionally, a portion of the structure of one embodiment can be replaced with the structure of another embodiment, and structures of other embodiments can be added to the structure of one embodiment. Regarding the structures of each embodiment, other structures can also be added, deleted, or replaced.

[0148] Explanation of reference numerals in the attached figures

[0149] 100 Crane System

[0150] 1. Crane

[0151] 2. Runway

[0152] 3 Main beam

[0153] 4 small cars

[0154] 5. Hoisting device

[0155] 6. Slings

[0156] 7. Hook

[0157] 8. Lifting steel cables

[0158] 9. Lifted loads

[0159] 10. Crane control device

[0160] 11 Positioning Control Unit

[0161] 11a Drive Parameter Determination Unit

[0162] 11b Drive signal output section

[0163] 12. Electric Motor Control Unit

[0164] 12a Speed ​​Command Value Generation Unit

[0165] 12b Load sway suppression control unit

[0166] 12c recording device

[0167] 132 Learning Outcomes

[0168] 140 Learning Devices

[0169] 150 cloud servers

[0170] 160 Local recording device

[0171] 20 Input / Output Device Group

[0172] 21 Controller

[0173] 22 Display devices

[0174] 23 Input devices

[0175] 30 Electric motor drive unit group

[0176] 31 Horizontal motor drive device

[0177] 32. Hoist motor drive unit

Claims

1. A crane system comprising: crane, It includes a winch device powered by an electric motor that moves the load vertically by lowering the hoisting cable, and a horizontal moving device powered by an electric motor that moves the load horizontally; a crane control device that outputs a speed command value corresponding to the target position of the load; and an electric motor drive device that supplies electrical power to the electric motor corresponding to the speed command value. The crane system is characterized in that: The positioning control unit of the crane control device includes: The recording unit records a dataset including the deceleration start time of the motor, the arrival position of the load, and the deceleration time of the motor when the load swing control is performed with a preset pendulum length. The drive parameter determination unit, based on the dataset, determines the start and stop times of the motor's deceleration according to the actual pendulum length and the target position of the suspended object during operation; and The drive signal output unit outputs drive signals according to the deceleration start time and the stopping time. The motor control unit of the crane control device includes: A speed command value generation unit, which generates a target speed command value for controlling the motor according to the drive signal; and The load swing suppression control unit generates a speed command value for suppressing the swing of the suspended object based on the target speed command value.

2. The crane system as described in claim 1, characterized in that: It has a target position input device for setting the target position of the hoisted object.

3. The crane system as described in claim 1 or 2, characterized in that: The dataset contains the load of the hoisted object. The drive parameter determination unit, based on the dataset, calculates the start and stop times of the motor's deceleration according to the actual pendulum length, the load of the suspended object, and the target position of the suspended object.

4. The crane system as described in claim 1 or 2, characterized in that: The drive parameter determination unit calculates the deceleration start time corresponding to the pendulum length and target position during actual operation by interpolation operation based on multiple datasets regarding the deceleration start time, and calculates the deceleration time corresponding to the pendulum length and target position during actual operation by interpolation operation based on multiple datasets regarding the deceleration time.

5. The crane system as described in claim 1 or 2, characterized in that: The drive parameter determination unit derives an approximate formula for calculating the deceleration start time and the deceleration time based on the dataset, and uses the approximate formula to calculate the deceleration start time and deceleration time during actual operation.

6. The crane system as described in claim 1 or 2, characterized in that: The drive parameter determination unit uses a neural network derived from the dataset to determine the deceleration start time and deceleration time during actual operation.

7. The crane system as described in claim 1 or 2, characterized in that, include: The first crane and the first crane control device; Second crane and second crane control device; and A cloud server is connected to the first crane control device and the second crane control device in a communicative manner. The dataset is recorded in the recording section of the cloud server, rather than in the recording section of each crane control device.

8. A control method executed by a crane control device of a crane system, the crane system comprising: A crane includes a winch device powered by an electric motor that moves a load vertically by lowering a hoisting cable, and a horizontal moving device powered by an electric motor that moves the load horizontally; a crane control device that outputs a speed command value corresponding to the target position of the load; and an electric motor drive device that supplies electrical power to the electric motor corresponding to the speed command value. The control method of the crane system is characterized by including: The steps of obtaining a dataset including the pendulum length during load swing control, the deceleration start time of the motor at the pendulum length, the arrival position of the load, and the deceleration time of the motor; Based on the dataset, the steps for determining the deceleration start and stop times of the motor according to the pendulum length and the target position of the suspended object during actual operation; The steps of outputting drive signals according to the deceleration start time and the stopping time; The step of generating a target speed command value for controlling the motor according to the drive signal; The steps of generating a speed command value for suppressing the swaying of the suspended object based on the target speed command value; and The step of supplying electrical power to the motor corresponding to the speed command value.

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