Anchoring control system and method for a portal crane

Abstract

The application belongs to the technical field of door machine control, and specifically provides an anchoring control system and method for a portal crane, which comprises an environment perception module, a self-positioning module, a decision control module and an execution module, wherein the environment perception module is used to collect environmental data around the portal crane and transmit the environmental data to the decision control module; the self-positioning module is used to collect positioning data of the portal crane and transmit the positioning data to the decision control module; the decision control module is used to generate a three-dimensional environment map according to the environmental data and generate an anchoring action instruction according to the three-dimensional environment map and the positioning data; and the execution module is used to control the portal crane to move and anchor to a target anchoring pit according to the anchoring action instruction. The technical solution provided by the application can improve the convenience of anchoring control of the portal crane.

Description

Technical Field

[0001] This application belongs to the field of gantry crane control technology, and particularly relates to an anchoring control system and method for a gantry crane. Background Technology

[0002] With the development of large-scale port operations, gantry cranes, as core equipment for steel loading and unloading, are increasingly used at single terminals. Windproof anchoring of these cranes under strong winds and extreme weather conditions has become a mandatory critical procedure for safe port operations, directly impacting the anti-slip and anti-overturning safety of the entire machine. Currently, gantry crane anchoring operations rely entirely on manual coordination, resulting in a cumbersome process and reliance on experience for human-machine collaboration, significantly reducing the ease of operation. The existing anchoring alignment process relies solely on the driver's experience and the assistance of yellow ground markings to determine the alignment position. Given that the gantry crane itself can weigh up to 550 tons, has significant inertia, and the gap between the anchor plate and the anchor pit is only 3cm, the alignment accuracy requirement is extremely high. During operation, there are issues of obstructed vision and signal transmission delays between the ground signalman and the driver. After the signalman issues a stop signal, the driver cannot brake immediately, requiring multiple back-and-forth adjustments to the trolley position, leading to lengthy alignment times. Therefore, improving the ease of gantry crane anchoring control is an urgent technical problem to be solved. Summary of the Invention

[0003] The embodiments of this application provide an anchoring control system, method, program product, readable storage medium, and electronic device for a gantry crane, thereby improving the convenience of anchoring control for gantry cranes.

[0004] Other features and advantages of this application will become apparent from the following detailed description, or may be learned in part from practice of this application.

[0005] According to a first aspect of the embodiments of this application, an anchoring control system for a gantry crane is provided, characterized in that the system includes an environmental perception module, a self-positioning module, a decision control module, and an execution module, wherein the environmental perception module is used to collect environmental data around the gantry crane and transmit the environmental data to the decision control module; the self-positioning module is used to collect positioning data of the gantry crane and transmit the positioning data to the decision control module; the decision control module is used to generate a three-dimensional environmental map based on the environmental data, and generate an anchoring action command based on the three-dimensional environmental map and the positioning data, wherein the three-dimensional environmental map is used to determine the occupancy status of each anchoring pit to filter the target anchoring pit of the gantry crane; the execution module is used to control the gantry crane to move and anchor to the target anchoring pit according to the anchoring action command.

[0006] In some embodiments of this application, based on the foregoing scheme, the environmental perception module includes a main sensor and an auxiliary safety sensor. The main sensor includes a lidar and a camera device, which are installed on the top of the gantry crane to acquire environmental data around the gantry crane. The auxiliary safety sensor includes a millimeter-wave radar and an ultrasonic radar. The millimeter-wave radar is installed in front of and behind the gantry crane in its traveling direction to detect obstacles in the gantry crane's traveling direction. The ultrasonic radar is installed around the anchor plate of the gantry crane to detect the alignment status of the anchor plate with the anchor pit.

[0007] In some embodiments of this application, based on the foregoing scheme, the decision control module includes an industrial control computer and a logic controller, wherein the industrial control computer is used to process the environmental data and perform three-dimensional modeling processing based on the environmental data to obtain a three-dimensional environmental map; the logic controller is used to generate anchoring action commands based on the three-dimensional environmental map and the positioning data.

[0008] In some embodiments of this application, based on the foregoing scheme, the self-positioning module includes: an absolute encoder, installed on the axle of the gantry crane, for detecting the mechanical angle of the axle; a wireless radio frequency positioner, for detecting the distance between the gantry crane and the anchoring pit; a laser rangefinder, for detecting the distance between the anchoring plate and the anchoring pit; and a communication device, for integrating the mechanical angle of the axle, the distance between the gantry crane and the anchoring pit, and the distance between the anchoring plate and the anchoring pit as positioning data, and transmitting the positioning data to the decision control module.

[0009] According to a second aspect of the embodiments of this application, an anchoring control method for a gantry crane is provided, characterized in that the method is executed in a system as described in the first aspect above, the method comprising: collecting environmental data around the gantry crane and positioning data of the gantry crane; constructing a three-dimensional environmental map based on the environmental data, and filtering target anchoring pits according to the three-dimensional environmental map; generating an anchoring action command according to the positioning data and the target anchoring pits; controlling the gantry crane to move to the target anchoring pits through the anchoring action command, and calibrating the position between the anchoring plate of the gantry crane and the target anchoring pits; and lowering the anchoring plate into the target anchoring pits after calibration to complete the anchoring operation.

[0010] In some embodiments of this application, based on the foregoing scheme, the collection of environmental data around the gantry crane includes: acquiring three-dimensional point cloud data of the environment around the gantry crane using a lidar, acquiring image data of the environment around the gantry crane using a camera device; and integrating the three-dimensional point cloud data and the image data as environmental data of the gantry crane.

[0011] In some embodiments of this application, based on the foregoing scheme, calibrating the position between the anchor plate of the gantry crane and the target anchoring pit includes: acquiring the longitudinal relative distance between the bottom of the gantry crane and the target anchoring pit, and the lateral relative distance between the anchor plate and the target anchoring pit; adjusting the position of the gantry crane based on the longitudinal and lateral relative distances until the longitudinal relative distance between the bottom of the gantry crane and the target anchoring pit is less than a first preset threshold, and the lateral relative distance between the anchor plate and the target anchoring pit is less than a second preset threshold.

[0012] According to a third aspect of the embodiments of this application, a computer program product is provided, the computer program product including computer instructions stored in a computer-readable storage medium and adapted to be read and executed by a processor to cause a computer device having the processor to perform an operation as described in any of the embodiments of the second aspect above.

[0013] According to a fourth aspect of the embodiments of this application, a computer-readable storage medium is provided, the computer-readable storage medium storing at least one computer program instruction, the at least one computer program instruction being loaded and executed by a processor to perform the operation performed by the method described in any one of the embodiments of the second aspect above.

[0014] According to a fifth aspect of the present application, an electronic device is provided, the electronic device including one or more processors and one or more memories, the one or more memories storing at least one computer program instruction, the at least one computer program instruction being loaded and executed by the one or more processors to perform the operation performed by the method as described in any of the embodiments of the second aspect above.

[0015] Based on the technical solution proposed in this application, an environmental perception module is set up to collect complete environmental data around the gantry crane and directly transmit it to the decision control module. A self-positioning module is set up to collect multi-level positioning data of the gantry crane and transmit it to the decision control module. The decision control module uses the environmental data to construct a three-dimensional environmental map and autonomously selects the target anchoring pit. Then, combined with the three-dimensional environmental map and real-time positioning data, a complete anchoring action command is generated. The execution module drives the equipment to move and align autonomously and complete the electric anchor locking. This can replace the traditional manual anchoring operation mode that relies on the cooperation of ground command workers and drivers, repeated adjustments of the trolley position by visually referring to ground markings, and manual lifting and placing of anchor plates on site. This eliminates the parking response delay caused by the human-machine line of sight difference, the alignment deviation caused by the trolley's own weight inertia, and the safety hazards of on-site operation in windy weather, thereby improving the convenience of gantry crane anchoring control.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. In the drawings: Figure 1 A schematic diagram of the anchoring control system of a gantry crane according to one embodiment of this application is shown; Figure 2 A schematic diagram of a wireless radio frequency locator in one embodiment of this application is shown; Figure 3 A flowchart of an anchoring control method for a gantry crane according to one embodiment of this application is shown; Figure 4 A schematic diagram of the structure of an electronic device according to one embodiment of this application is shown. Detailed Implementation

[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0020] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0021] The flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0022] It should also be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such uses of these terms can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described.

[0023] With the development of large-scale port operations, gantry cranes, as core equipment for steel loading and unloading, have seen a continuous increase in the number of gantry cranes per terminal. Windproof anchoring of equipment under strong winds and extreme weather conditions has become a mandatory key process for safe port operations, directly affecting the anti-slip and anti-overturning safety of the entire machine. Current gantry crane anchoring operations rely entirely on manual coordination, resulting in a cumbersome process and reliance on experience for human-machine cooperation, significantly reducing the convenience of gantry crane anchoring operations. The existing anchoring alignment process relies solely on the driver's experience and the assistance of yellow ground markings to determine the alignment position. Given that the gantry crane itself can weigh up to 550 tons, has significant inertia, and the gap between the anchoring plate and the anchoring pit is only 3cm, the alignment accuracy requirements are extremely high. During operations, there are issues of obstructed vision and signal transmission delays between the ground signalman and the driver in the cab. After the signalman issues a stop signal, the driver cannot brake immediately and needs to make multiple trips to adjust the trolley position, resulting in lengthy alignment times. Therefore, this application proposes an anchoring control system and method for gantry cranes to improve the convenience of gantry crane anchoring control.

[0024] Next, we will combine Figure 1 The anchoring control system of the gantry crane proposed in this application is described in detail.

[0025] See Figure 1 This illustration shows a schematic diagram of the anchoring control system of a gantry crane according to one embodiment of this application, as follows: Figure 1 As shown, the system may include at least an environmental perception module 110, a self-localization module 120, a decision control module 130, and an execution module 140. The environmental perception module 110 can collect environmental data around the gantry crane and transmit the environmental data to the decision control module 130. The self-localization module 120 can collect positioning data of the gantry crane and transmit the positioning data to the decision control module 130. The decision control module 130 can generate a three-dimensional environmental map based on the environmental data and generate an anchoring action command based on the three-dimensional environmental map and the positioning data. The three-dimensional environmental map is used to determine the occupancy status of each anchoring pit to filter the target anchoring pit for the gantry crane. The execution module 140 is used to control the gantry crane to move and anchor to the target anchoring pit according to the anchoring action command.

[0026] In this application, the gantry crane (i.e., gantry crane) refers to a large-scale lifting equipment for loading and unloading at port terminals. A single machine can weigh up to 550 tons. The equipment travels back and forth along the tracks laid on the dock. In windy weather, it is necessary to rely on the anchoring structure to lock the machine body to prevent the equipment from slipping or overturning.

[0027] In this application, the environmental perception module is the external information acquisition unit of the anchoring control system. It relies on the fusion of multiple types of sensors to capture surrounding environmental information. The module contains two types of hardware: main sensors and auxiliary safety sensors. The main sensors include a multi-line mechanical lidar and a high-definition camera device, while the auxiliary safety sensors include millimeter-wave radar and ultrasonic radar. Each type of sensor collects environmental information at different distances and under different weather conditions. After integration, the collected information forms a unified environmental data set for output. The environmental data refers to the collection of all information collected by various sensors, including a 360° three-dimensional point cloud generated by lidar scanning, real-scene images captured by the camera device and identified by artificial intelligence algorithms, millimeter-wave long-range obstacle detection values, ultrasonic short-range gap detection values, and all environmental information such as obstacles along the gantry crane's travel path, the outline of each anchoring pit, and obstructing objects around the pit.

[0028] In this application, the self-positioning module is a hardware unit used to determine the real-time spatial position of the gantry crane. It is equipped with multiple positioning devices, including an absolute encoder installed at the axle of the walking motor, an RFID locator (radio frequency locator) with magnetic nails embedded beside the track, a laser range sensor at the bottom of the gantry crane, and a Beidou GPS device that provides geographic coordinates. The entire unit continuously collects the device's own position-related information to form positioning data, which is synchronously pushed to the decision control module to complete position calibration and calculation. The positioning data refers to all position-related information output by the self-positioning module, including the mechanical angle value of the walking mechanism read by the absolute encoder, the ground magnetic nail landmark position code read by the RFID locator, the relative distance between the gantry crane and the anchor pit measured by the laser range sensor, and the absolute geographic coordinates of the device output by the Beidou GPS. This type of data can continuously provide feedback on the current driving position of the gantry crane, the remaining distance between the gantry crane and the anchor pit, and its own walking deviation.

[0029] In this application, the decision control module is the core unit for data processing and instruction generation of the system. It adopts a division of labor architecture with an industrial control computer and a programmable logic controller. The industrial control computer is responsible for environmental data 3D modeling, anchor occupancy status identification, and walking path calculation. The programmable logic controller is responsible for receiving modeling results and positioning data to generate standardized motion instructions, while monitoring the equipment's operational safety status throughout the process and outputting an emergency stop control signal when an abnormality occurs.

[0030] In this application, the execution module is the mechanical motion drive unit of the system, which includes a modified electric anchoring device, an integrated control variable frequency walking mechanism, and a hierarchical human-machine interaction device. The human-machine interaction device includes a local touch screen in the driver's cab, a central control remote control console, and a field handheld remote control terminal. After receiving the anchoring action command, the module synchronously drives the walking mechanism and the anchoring mechanism to complete the corresponding mechanical action.

[0031] In this application, an environmental perception module is set up to collect complete environmental data around the gantry crane and transmit it directly to the decision control module. A self-positioning module is set up to collect multi-level positioning data of the gantry crane and transmit it to the decision control module. The decision control module uses the environmental data to construct a three-dimensional environmental map and autonomously selects the target anchoring pit. Then, it combines the three-dimensional environmental map with real-time positioning data to generate a complete anchoring action command. The execution module drives the equipment to move and align autonomously and complete the electric anchor locking. This can replace the traditional manual anchoring operation mode that relies on the cooperation of ground commanders and drivers, repeated adjustment of the trolley position by visually referring to ground markings, and manual lifting and placing of anchor plates on site. This eliminates the parking response delay caused by the human-machine line of sight difference, the alignment deviation caused by the trolley's own weight inertia, and the safety hazards of on-site operation in windy weather, thereby improving the convenience of gantry crane anchoring control.

[0032] Continue to refer to Figure 1 The environmental perception module 110 may include at least a main sensor 111 and an auxiliary safety sensor 112. The main sensor 111 may include at least a lidar and a camera device, which are installed on the top of the gantry crane and can be used to acquire environmental data around the gantry crane. The auxiliary safety sensor 112 may include at least a millimeter-wave radar and an ultrasonic radar. The millimeter-wave radar is installed in front of and behind the gantry crane in its traveling direction and is used to detect obstacles in the gantry crane's traveling direction. The ultrasonic radar is installed around the anchor plate of the gantry crane and is used to detect the alignment status of the anchor plate of the gantry crane with the anchor pit.

[0033] In this application, the main sensor is a combination of sensing devices used for environmental data acquisition in the environmental perception module. It is the main data source for generating 3D environmental maps and identifying anchor pits and obstacles, and is responsible for collecting environmental information over a wide range and from all angles under normal working conditions. The auxiliary safety sensor is a combination of sensing devices that supplements the application limitations of the main sensor. It focuses on adapting to severe weather, accurate close-range detection, and active collision avoidance protection. It is used to make up for the perception shortcomings of the main sensor in specific scenarios and build a safety perception system with redundancy capabilities.

[0034] In this application, the lidar can measure the target distance and spatial contour by emitting a laser beam. Specifically, it can adopt a multi-line mechanical structure to output high-precision three-dimensional point cloud data. The camera device can be an image acquisition device equipped with artificial intelligence recognition algorithms, which can capture surrounding real-world images and identify object categories, providing semantic information that the laser point cloud cannot cover to the decision control module, thus enriching the dimensions of environmental data.

[0035] In this application, the millimeter-wave radar refers to a detection radar that operates in the millimeter-wave band. It has the characteristics of being unaffected by light, rain, fog, and dust, and can realize long-distance obstacle detection. It is mostly used for active collision avoidance protection under harsh working conditions. The ultrasonic radar refers to a sensing device that relies on ultrasonic wave reflection to measure close-range gaps. It has high detection accuracy but short effective range. It is mostly used for detecting minute gaps and preventing scratches when equipment is close to a target.

[0036] In this application, the lidar and the camera device are installed on the top of the gantry crane. This position provides a wide field of view without obstruction from the crane's own structure, covering a 360° area around the equipment to ensure the integrity of environmental data collection. The lidar is a multi-line mechanical type that continuously emits laser beams to scan the surrounding space and outputs high-precision 3D point cloud data. This data can accurately reconstruct the dock track alignment, the spatial outline of each anchorage pit, and the shape, size, and relative position of surrounding obstacles, providing basic data for subsequent 3D environmental mapping. The camera device is a high-definition network camera equipped with an artificial intelligence recognition algorithm. It can identify the specific types of objects in the scene while collecting real-world images, distinguishing between different obstacles such as other gantry cranes, steel piles, and workers. This provides the decision-making and control module with object category information that the laser point cloud cannot cover, enriching the dimensions of the environmental data.

[0037] In this application, the millimeter-wave radar and ultrasonic radar correspond to two different safety scenarios: long-distance walking collision avoidance and close-range alignment protection. Together, they form a safety defense line at the perception level. The millimeter-wave radar focuses on long-distance, harsh working conditions for path obstacle detection, while the ultrasonic radar focuses on short-distance, high-precision alignment gap detection. The division of labor between the two covers the safety perception needs of different distance ranges, providing supplementary and backup protection for the normal operation of the main sensor.

[0038] In this application, the millimeter-wave radar is installed at the front and rear ends of the gantry crane's trolley in the direction of travel, facing the track direction of the trolley's movement. The detection range can reach more than 50m, enabling it to detect obstacles on the travel path in advance. The core advantage of millimeter-wave radar is that it is not affected by weather conditions such as light, rain, fog, and sandstorms. Even in harsh environments such as heavy fog and rainstorms, which reduce the perception accuracy of lidar and camera devices, it can still stably detect whether there are other equipment, leftover materials, or other obstacles ahead, and synchronize the detection data to the decision control module to realize active collision avoidance warning and automatic deceleration and avoidance. As a supplementary solution to the main sensor in harsh weather conditions, it ensures the safety of the automated travel process.

[0039] In this application, the ultrasonic radar is arranged around the anchor plate, with a detection range controlled within 3m. It is a high-precision short-range detection device. When the gantry crane travels to the vicinity of the anchor pit, the ultrasonic radar starts working and measures the lateral gap between the anchor plate and the side wall of the anchor pit in real time, as well as the longitudinal relative distance between the plate and the edge of the pit. This reflects the alignment status of the two, ensuring that the anchor plate and the pit are accurately aligned, avoiding scratches during the lowering process, and ensuring the smooth completion of the anchoring action.

[0040] In this application, by dividing the environmental perception module into a main sensor and an auxiliary safety sensor, a lidar and camera device are installed on the top of the gantry crane to complete large-scale, all-area environmental data collection, millimeter-wave radar is arranged in front and behind the traveling direction to achieve long-distance obstacle detection, and ultrasonic radar is installed around the anchor plate to detect the alignment status. This allows for the construction of a complete environmental perception system covering the entire distance range and all weather conditions. It can rely on the high-precision data output by the main sensor on the top to support the construction of a three-dimensional environmental map and the selection of anchor pits. It can also use millimeter-wave radar to compensate for the reduced perception capability of the main sensor under adverse weather conditions. Furthermore, the accurate detection of the near-range ultrasonic radar can meet the alignment requirements of the narrow gaps in the anchor pits, reduce the alignment judgment error caused by line of sight obstruction and weather factors, reduce the number of times the trolley needs to be adjusted, and avoid the safety risks of personnel working on-site in adverse weather conditions. This effectively improves the accuracy and efficiency of anchor alignment and enhances the convenience of gantry crane anchor control.

[0041] Continue to refer to Figure 1 The decision control module 130 may include at least an industrial computer 131 and a logic controller 132. The industrial computer 131 may be used to process the environmental data and perform three-dimensional modeling processing based on the environmental data to obtain a three-dimensional environmental map. The logic controller 132 may be used to generate anchoring action commands based on the three-dimensional environmental map and the positioning data.

[0042] In this application, the industrial control computer is a hardware unit in the decision control module that undertakes complex data operations and intelligent decision-making. It has strong parallel data processing capabilities and is suitable for processing massive amounts of sensing data and spatial modeling operations. The logic controller is a hardware unit in the decision control module that undertakes real-time motion control and command output. It has high reliability and strong real-time response characteristics and can be directly connected to the field actuator to complete motion control and safety status monitoring.

[0043] In this application, the industrial control computer is geared towards processing massive amounts of non-real-time sensing data and complex spatial modeling calculations, while the logic controller is geared towards executing high real-time motion control to generate motion commands and monitor equipment status. The two can interact via industrial Ethernet, collaborating to complete the entire decision-making process from environmental data analysis to motion command output. This ensures both the processing accuracy of complex modeling calculations and the millisecond-level control response requirements for walking and anchoring actions, providing stable and reliable decision support for the entire automated anchoring process.

[0044] In this application, during the data processing stage, the industrial control computer receives all environmental data transmitted by the environmental perception module. It can perform noise reduction, distortion correction, and point cloud stitching on the 3D point cloud output by the lidar, and perform object recognition and semantic annotation on the images collected by the camera device. Then, it performs spatial coordinate registration and feature fusion on the two types of data from different sources to form standardized original spatial data in a unified format. In the 3D modeling stage, based on the fused environmental data, the industrial control computer restores the complete route of the wharf track, the spatial outline and coordinates of each anchorage pit, and the shape and distribution range of obstacles around the track. At the same time, it marks the occupancy status of each anchorage pit to clearly distinguish whether the pit is occupied by other equipment. The final generated 3D environmental map can not only intuitively present the spatial layout of the entire wharf area, but also support the system to filter vacant target anchorage pits according to preset priorities and plan the optimal safe walking path to avoid obstacles.

[0045] In this application, the logic controller receives a 3D environment map from the industrial control computer, extracts the coordinate information of the target anchoring pit and the avoidance boundary requirements of surrounding obstacles, and reads the real-time positioning data uploaded by the self-positioning module to determine the current accurate position of the gantry crane. Combining the target anchoring coordinates with the current position of the equipment, the logic controller calculates a travel path that conforms to the operating characteristics of the equipment, sets the acceleration, constant speed, and deceleration nodes of the trolley travel, plans the micro-adjustment step size when approaching the anchoring pit, and matches the lowering sequence and positioning judgment conditions of the anchoring plate. It also sets safety monitoring thresholds such as motor current and running speed. When abnormal parameters occur, it can directly trigger emergency stop protection. Finally, it integrates to form a complete anchoring action command.

[0046] In this application, by setting the decision control module as an industrial control computer and a logic controller, the industrial control computer completes environmental data processing and 3D modeling to obtain a 3D environment map, and then the logic controller combines the 3D environment map and real-time positioning data to generate standardized anchoring action commands. This can separate the complex spatial modeling calculations and the high real-time motion control, ensuring the modeling accuracy of the 3D environment map and the accuracy of anchor position identification, avoiding excessive computational load that could cause delays in motion control, and effectively improving the convenience of anchoring control for gantry cranes.

[0047] Continue to refer to Figure 1The self-positioning module 120 may include at least an absolute encoder 121, a wireless radio frequency positioner 122, a laser rangefinder 123, and a communication device 124. The absolute encoder 121 is mounted on the axle of the gantry crane and is used to detect the mechanical angle of the axle. The wireless radio frequency positioner 122 is used to detect the distance between the gantry crane and the anchoring pit. The laser rangefinder 123 is used to detect the distance between the anchoring plate and the anchoring pit. The communication device 124 is used to integrate the mechanical angle of the axle, the distance between the gantry crane and the anchoring pit, and the distance between the anchoring plate and the anchoring pit as positioning data, and transmit the positioning data to the decision control module.

[0048] In this application, the absolute encoder is a position detection device that can directly output the mechanical angle of the rotating shaft. The position information will not be lost after power failure, and it can output valid position data without power-on and zeroing. It is the basic hardware for continuous positioning of the gantry crane when traveling long distances. The mechanical angle is the real-time rotation angle value of the traveling wheel axle or motor shaft. This value has a fixed geometric conversion relationship with the linear displacement of the wheel travel. The cumulative travel distance of the gantry crane along the track can be directly obtained by angle calculation.

[0049] In this application, the wireless radio frequency locator is a device that uses wireless radio frequency identification technology to achieve fixed-point location detection. It consists of a vehicle-mounted reading and writing device and a ground-embedded coded marker. When the device passes the marker point, it can read the reference coordinates to correct the cumulative error caused by continuous positioning. The laser range sensor is a device that uses the principle of laser reflection to achieve high-precision distance measurement. The measurement accuracy can reach the millimeter level. It is mostly used for close-range distance detection when the device is close to the target, providing data support for fine-tuning the alignment.

[0050] In this application, the communication device can be used for multi-source positioning data format conversion and integrated transmission. It can uniformly convert sensor data with different communication protocols into a standard format that the control system can recognize, ensuring stable transmission of positioning data to the decision-making end. The positioning information is a unified set of position information integrated by the communication device, which includes three types of data: basic displacement converted from wheel and axle mechanical angle, fixed reference position, and close-range alignment distance. It can completely characterize the real-time position and alignment status of the gantry crane.

[0051] Please refer to the following in this application: Figure 2 The diagram shows a schematic of a wireless radio frequency locator in one embodiment of this application, such as... Figure 2As shown, the wireless radio frequency locator consists of an on-board reading and writing unit and multiple coded markers pre-embedded along the track. The markers are arranged along the track at fixed intervals. One marker is set 4m outward from each side of the anchor pit, and the markers are evenly distributed at 8m intervals in the area extending outward. When the gantry crane travels over the markers, the on-board reading and writing unit can read the reference coordinate information stored in the markers to determine the accurate distance between the equipment and the anchor pit. At the same time, the reference coordinates are used to correct the position deviation accumulated by the absolute encoder and synchronize the encoder value. This can serve as a position calibration node during long-distance travel and also provide a precise position reference when the equipment approaches the anchor pit, helping the system determine when the equipment enters the alignment fine-tuning stage.

[0052] In this application, the laser rangefinder sensor is installed at the bottom of the gantry crane, specifically facing the anchoring pit, and is a high-precision short-range detection device. When the gantry crane travels to the vicinity of the anchoring pit and enters the fine-tuning stage, the laser rangefinder sensor starts working, measuring the longitudinal relative distance between the anchor plate and the anchoring pit in real time, that is, the alignment gap of the trolley along the travel direction. It can accurately capture the distance changes caused by the slight movement of the trolley, providing data for the position fine-tuning before entering the pit, and ensuring that the anchor plate is precisely aligned with the pit in the travel direction.

[0053] In this application, the communication device can receive raw detection data output from three types of sensors, convert mechanical angles into standard displacement values, combine them with the reference coordinates of the wireless radio frequency positioner to complete error correction, and then match the close-range alignment data from laser ranging. This data is integrated into a unified, complete positioning data packet, which is then stably transmitted to the decision control module via an industrial fieldbus. The integrated positioning data includes both long-distance continuous position information and high-precision data for fixed-point calibration and close-range fine-tuning, simultaneously supporting both long-distance trolley movement control and precise anchoring pit alignment requirements.

[0054] In this application, by setting up an absolute encoder, a wireless radio frequency positioner, a laser rangefinder, and a communication device within the self-positioning module, the absolute encoder on the wheel axle continuously detects mechanical angles to provide a basis for long-distance continuous positioning. The wireless radio frequency positioner uses the distance between the fixed-point detection device and the anchoring pit to correct the accumulated positioning error. Then, the laser rangefinder collects the close distance between the anchoring plate and the pit to achieve fine-tuning of the positioning. Finally, the communication device integrates all position data and transmits it to the decision control module. This can construct a hierarchical and progressive positioning system, dynamically outputting real-time position and alignment gap data of the device, reducing the number of times the trolley needs to repeatedly adjust its position, thereby shortening the time required for anchoring and alignment, and improving the ease of operation for anchoring and alignment.

[0055] Next, we will combine Figure 3The anchoring control method for the gantry crane proposed in this application is described in detail.

[0056] See Figure 3 The flowchart illustrates an anchoring control method for a gantry crane according to one embodiment of this application, as shown below. Figure 3 As shown, the method may include at least the following steps 310 to 350: Step 310: Collect environmental data around the gantry crane and positioning data of the gantry crane.

[0057] Step 320: Construct a three-dimensional environmental map based on the environmental data, and filter target anchoring locations according to the three-dimensional environmental map.

[0058] Step 330: Generate an anchoring action command based on the positioning data and the target anchoring pit location.

[0059] Step 340: Control the gantry crane to move to the target anchoring pit position through the anchoring action command, and calibrate the position between the anchoring plate of the gantry crane and the target anchoring pit position.

[0060] Step 350: After calibration, lower the anchoring plate into the target anchoring pit to complete the anchoring operation.

[0061] In this application, after receiving the start command, the system initiates two types of data acquisition: environmental perception and self-localization, to provide accurate raw materials for subsequent calculations. The lidar continuously scans the surrounding space and outputs a three-dimensional point cloud, the camera device simultaneously acquires real-scene images and identifies obstacle types, the millimeter-wave radar detects obstacles at a distance, the absolute encoder reads mechanical angles in real time to calculate walking displacement, the wireless radio frequency locator continuously monitors the pre-embedded marker points on the track, and the laser rangefinder is on standby for close-range detection.

[0062] In this application, after receiving the cached environmental data, the industrial control computer first performs noise reduction, registration, and fusion processing on the original data. Then, it reconstructs the spatial structure of the entire dock track area through 3D modeling calculations, generating a complete 3D environmental map. This 3D environmental map includes occupancy status indicators for each anchorage location and obstacle avoidance zones around the track. After the map is built, the system sequentially searches for the occupancy indicators of each anchorage location according to a preset priority order. If a location is occupied, the search automatically continues to the next location until a suitable vacant location is selected as the target anchorage location. In this application, the logic controller reads the coordinates of the target anchoring pit issued by the industrial control computer, and continuously reads the real-time positioning data of the gantry crane. It calculates the optimal safe walking path by combining the current position of the equipment with the target position, sets motion commands according to the operating characteristics of the gantry crane, plans the micro-adjustment step size and calibration accuracy threshold when approaching the anchoring pit, and sets the lowering trigger conditions and positioning judgment rules for the anchoring plate. Finally, it integrates these into a complete anchoring action command.

[0063] In this application, controlling the gantry crane to move to the target anchoring pit is divided into two stages: long-distance travel and close-range calibration. In the long-distance travel stage, after receiving the anchoring action command, the execution module drives the trolley traveling mechanism to travel along the planned path. During the travel, the speed control is maintained by the positioning data provided by the absolute encoder. When passing the radio frequency marker, the cumulative positioning error is automatically corrected. At the same time, the obstacle on the path is avoided by relying on the environmental perception data. When the crane reaches the vicinity of the target anchoring pit, it enters the close-range calibration stage. The laser rangefinder collects the longitudinal distance between the anchoring plate and the pit, and the ultrasonic radar collects the lateral gap data. The logic controller repeatedly outputs micro-adjustment commands according to the real-time gap value, controlling the trolley to move slightly forward and backward and left and right, gradually reducing the alignment gap until the alignment accuracy between the anchoring plate and the pit meets the dimensional requirements, thus completing the calibration process.

[0064] In this application, when the system determines that the alignment calibration has met the standard, the execution module drives the electric anchoring device to operate, and the electric push rod drives the anchoring plate to be lowered smoothly, so that the plate is embedded in the target anchoring pit. After the plate descends to the set position, the limit sensor feeds back the position signal, and the system determines that the anchoring operation is completed.

[0065] In this application, by sequentially executing a complete automated process of environmental and positioning data acquisition, 3D environmental map construction and target anchor selection, anchoring action command generation, equipment movement and alignment calibration, and electric anchoring to complete the operation, the parking error caused by obstructed vision and reaction delay is eliminated. It also eliminates the need for personnel to manually operate the anchoring plate, reduces the number of times the trolley needs to repeatedly adjust the alignment, shortens the overall anchoring operation time, and effectively improves the convenience of gantry crane anchoring control.

[0066] In step 310 above, the collection of environmental data around the gantry crane can be specifically performed according to steps 311 to 312 as follows: Step 311: Obtain three-dimensional point cloud data of the environment surrounding the gantry crane using lidar, and obtain image data of the environment surrounding the gantry crane using a camera device.

[0067] Step 312: Integrate the 3D point cloud data and the image data as environmental data for the gantry crane.

[0068] In this application, the lidar can be a multi-line mechanical type, installed on the top of the gantry crane around the perimeter, enabling 360° full-area scanning. When the equipment is running, it continuously emits laser beams to the surrounding area, calculates the three-dimensional coordinates of each reflection point by receiving the reflected signals, and outputs three-dimensional point cloud data. This data can completely restore the direction of the dock track, the spatial outline and size of each anchoring pit, and the shape and relative distance of obstacles around the track, which is the spatial data source for subsequent construction of a three-dimensional environmental map.

[0069] In this application, the camera device is a high-definition network acquisition device that continuously acquires surrounding real-world images during operation to obtain image data. The device is equipped with an artificial intelligence recognition algorithm that can analyze the acquired images and identify different types of objects in the image, such as other gantry cranes, steel piles, workers, and on-site facilities. It can extract the category attribute information of the objects, which can help the system distinguish the specific types of obstacles and provide richer judgment basis for subsequent avoidance strategy formulation.

[0070] In this application, because the coordinate systems and data formats of 3D point cloud data and image data are completely different, they cannot be directly used together for environment modeling. Therefore, integration processing is required first. During the integration process, spatial coordinate registration is first completed, mapping the pixel coordinates of the image to the spatial coordinates of the 3D point cloud, ensuring that every object in the image matches its corresponding spatial contour in the point cloud. Then, the object category labels obtained from image recognition are associated with the corresponding point cloud regions. Finally, the data is fused to obtain environmental data with a unified format and complete information. The integrated environmental data contains both high-precision spatial dimensions and location information, as well as category attribute information of each object in the scene. It can simultaneously support the spatial construction of 3D environment maps and the determination of anchor pit occupancy status, and can also provide type-based information for obstacle avoidance decisions. The entire set of data is transmitted to the decision control module in real time, providing basic data support for subsequent full-process decision calculations.

[0071] In this application, by using LiDAR to acquire 3D point cloud data and camera devices to acquire image data when collecting environmental data, and then integrating the two types of data into unified environmental data, high-precision spatial contour information and object category semantic information of the surrounding scene can be obtained simultaneously. This allows the environmental data to have both accurate spatial dimensions and rich attribute information, enabling a more accurate reconstruction of the real environment at the dock site. It also enables more reliable identification of obstacle types on the walking path and the formulation of avoidance strategies, reducing the number of times the trolley needs to be repeatedly adjusted for alignment, and improving the accuracy of anchoring and alignment and operational efficiency.

[0072] In step 340 above, the calibration of the position between the anchor plate of the gantry crane and the target anchoring pit can be specifically performed according to steps 341 to 342 as follows: Step 341: Collect the longitudinal relative distance between the bottom of the gantry crane and the target anchoring pit, and the lateral relative distance between the anchoring plate and the target anchoring pit.

[0073] Step 342: Adjust the position of the gantry crane based on the longitudinal relative distance and the lateral relative distance until the longitudinal relative distance between the bottom of the gantry crane and the target anchoring pit is less than a first preset threshold, and the lateral relative distance between the anchoring plate and the target anchoring pit is less than a second preset threshold.

[0074] In this application, the longitudinal relative distance is the straight-line distance between the bottom reference surface of the equipment and the edge of the target anchoring pit along the direction of the gantry crane's trolley travel track, corresponding to the alignment deviation in the front-to-back direction of the trolley, and is a parameter for determining whether the travel direction is aligned; the lateral relative distance is the gap distance between the side wall of the anchoring plate and the inner side wall of the target anchoring pit in the direction perpendicular to the trolley travel track, corresponding to the alignment deviation in the left-to-right direction of the trolley, and is a parameter for determining whether the plate can fall smoothly into the pit.

[0075] In this application, the first preset threshold is a pre-set longitudinal alignment qualification standard, the value of which matches the gap size between the anchor plate and the anchor pit. When the longitudinal relative distance is less than the threshold, it can ensure that the plate is completely aligned with the pit opening in the walking direction. The second preset threshold is a pre-set lateral alignment qualification standard, which is also adapted to the fitting gap requirements of the anchor structure. When the lateral relative distance is less than the threshold, it can ensure that the plate will not scrape against the pit wall during the lowering process.

[0076] In this application, the longitudinal relative distance is acquired by a laser rangefinder sensor installed at the bottom of the gantry crane. The sensor faces the edge reference surface of the target anchoring pit, achieving a measurement accuracy down to the millimeter level. This sensor can reflect the front-to-back alignment deviation of the trolley along the track in real time, and the data is continuously updated as the trolley moves. The lateral relative distance is acquired by an ultrasonic radar arranged around the anchoring plate. The radar faces the inner wall of the anchoring pit, capturing the left and right gaps between the plate and the pit wall in real time, reflecting the lateral alignment deviation. Both types of data are acquired and output simultaneously, eliminating the need for on-site personnel to measure the gaps or for the driver to rely on ground markings and personal experience to estimate the alignment status. This ensures a stable and accurate output of alignment values.

[0077] In this application, when the longitudinal relative distance exceeds a first preset threshold, the logic controller outputs a low-speed travel command, controlling the trolley to move slightly back and forth along the track direction, gradually reducing the longitudinal gap. The travel speed decreases as it approaches the threshold to prevent the trolley from overshooting the target position due to its large weight. When the lateral relative distance exceeds a second preset threshold, the system synchronously controls the trolley to complete a slight lateral adjustment, reducing the alignment deviation in the left and right directions, until the longitudinal relative distance is less than the first preset threshold and the lateral relative distance is less than the second preset threshold. In this application, by simultaneously collecting longitudinal and lateral relative distances during the calibration process, and continuously adjusting the position of the gantry crane based on these distances until both distances meet their respective preset accuracy thresholds, the alignment accuracy can be controlled simultaneously from both front-to-back and left-to-right directions. This method relies on sensor-based quantitative detection to replace the traditional method of manually observing ground markings to determine alignment, eliminating alignment errors caused by personnel obstruction, signal transmission delays, and the inertia of the equipment's own weight. It avoids the need for the trolley to repeatedly adjust its position, ensuring stable alignment requirements for the narrow gaps in the anchoring structure. This shortens the calibration time, improves alignment accuracy, and further enhances the convenience of anchoring control.

[0078] Based on the technical solution proposed in this application, an environmental perception module is set up to collect complete environmental data around the gantry crane and directly transmit it to the decision control module. A self-positioning module is set up to collect multi-level positioning data of the gantry crane and transmit it to the decision control module. The decision control module uses the environmental data to construct a three-dimensional environmental map and autonomously selects the target anchoring pit based on the map. Then, combined with the three-dimensional environmental map and real-time positioning data, a complete anchoring action command is generated. The execution module drives the equipment to move and align autonomously and complete the electric anchor locking. This can replace the traditional manual anchoring operation mode that relies on the cooperation of ground command workers and drivers, repeated adjustment of the trolley position by visually referring to ground markings, and manual lifting and placing of anchor plates on site. This eliminates the parking response delay caused by the human-machine line of sight difference, the alignment deviation caused by the trolley's own weight inertia, and the safety hazards of on-site operation in windy weather, thereby improving the convenience of gantry crane anchoring control.

[0079] As another embodiment of this application, a computer program product or computer program is also provided, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the methods described in the above embodiments.

[0080] As another embodiment of this application, a computer-readable storage medium is also provided. This computer-readable storage medium may be included in the electronic device described in the above embodiments; or it may exist independently and not assembled into the electronic device. The aforementioned computer-readable storage medium carries one or more programs, which, when executed by the electronic device, cause the electronic device to perform the methods described in the above embodiments.

[0081] Based on the same inventive concept, embodiments of this application also provide an electronic device. (Reference) Figure 4 The diagram illustrates the structure of an electronic device according to one embodiment of this application. The electronic device includes one or more memories 404, one or more processors 402, and at least one computer program (program code) stored in the memories 404 and executable on the processors 402. When the processors 402 execute the computer program, they implement the method described above.

[0082] Among them, Figure 4 In this document, a bus architecture (represented by bus 400) is used. Bus 400 may include any number of interconnected buses and bridges, linking various circuits including one or more processors represented by processor 402 and memory represented by memory 404. Bus 400 may also link various other circuits such as peripheral devices, voltage regulators, and power management circuits, which are well known in the art and therefore will not be described further herein. Bus interface 405 provides an interface between bus 400 and receiver 401 and transmitter 403. Receiver 401 and transmitter 403 may be the same element, i.e., a transceiver, providing a unit for communicating with various other devices over a transmission medium. Processor 402 is responsible for managing bus 400 and general processing, while memory 404 can be used to store data used by processor 402 during operation.

[0083] The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions may be stored as one or more instructions or codes on or transmitted via a computer-readable medium. Other examples and embodiments are within the scope and spirit of this application and the appended claims. For example, due to the nature of software, the functions described above may be implemented using software executed by a processor, hardware, firmware, hardwired, or any combination thereof. Furthermore, the functional units may be integrated into a single processing unit, or each unit may exist physically separately, or two or more units may be integrated into a single unit.

[0084] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The device embodiments described above are merely illustrative; for example, the division of units can be a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling, direct coupling, or communication connection may be through some interfaces; the indirect coupling or communication connection between units or modules may be electrical or other forms.

[0085] The units described as separate components may or may not be physically separate. Similarly, the components of the control device may or may not be physical units; they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0086] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, read-only memory (ROM), random access memory (RAM), portable hard drive, magnetic disk, or optical disk.

[0087] The above description is merely an embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. An anchoring control system for a gantry crane, characterized in that, The system includes an environmental perception module, a self-localization module, a decision control module, and an execution module, wherein... The environmental perception module is used to collect environmental data around the gantry crane and transmit the environmental data to the decision control module. The self-positioning module is used to collect the positioning data of the gantry crane and transmit the positioning data to the decision control module; The decision control module is used to generate a three-dimensional environmental map based on the environmental data, and to generate anchoring action instructions based on the three-dimensional environmental map and the positioning data. The three-dimensional environmental map is used to determine the occupancy status of each anchoring pit to filter the target anchoring pit of the gantry crane. The execution module is used to control the gantry crane to move and anchor to the target anchoring pit according to the anchoring action command.

2. The system according to claim 1, characterized in that, The environmental perception module includes a main sensor and auxiliary safety sensors, wherein... The main sensor includes a lidar and a camera device, which are mounted on the top of the gantry crane to acquire environmental data around the gantry crane. The auxiliary safety sensors include millimeter-wave radar and ultrasonic radar. The millimeter-wave radar is installed in front of and behind the gantry crane in the direction of travel to detect obstacles in the direction of travel of the gantry crane. The ultrasonic radar is installed around the anchor plate of the gantry crane to detect the alignment status of the anchor plate with the anchor pit.

3. The system according to claim 2, characterized in that, The decision control module includes an industrial control computer and a logic controller, wherein... The industrial control computer is used to process the environmental data and perform three-dimensional modeling based on the environmental data to obtain a three-dimensional environmental map; The logic controller is used to generate anchoring action commands based on the three-dimensional environment map and the positioning data.

4. The system according to claim 3, characterized in that, The self-localization module includes: An absolute encoder is installed on the axle of the gantry crane to detect the mechanical angle of the axle; A wireless radio frequency locator is used to detect the distance between the gantry crane and the anchoring pit. A laser rangefinder sensor is used to detect the distance between the anchor plate and the anchor pit. A communication device is used to integrate the mechanical angle of the wheel axle, the distance between the gantry crane and the anchoring pit, and the distance between the anchoring plate and the anchoring pit as positioning data, and transmit the positioning data to the decision control module.

5. An anchoring control method for a gantry crane, characterized in that, The method is performed on the system as described in claim 1, and the method includes: Collect environmental data around the gantry crane, as well as the positioning data of the gantry crane; A three-dimensional environmental map is constructed based on the environmental data, and target anchoring locations are selected based on the three-dimensional environmental map; Based on the positioning data and the target anchoring pit location, an anchoring action command is generated; The anchoring action command controls the gantry crane to move to the target anchoring pit and calibrates the position between the anchoring plate of the gantry crane and the target anchoring pit. After calibration, the anchoring plate is lowered into the target anchoring pit to complete the anchoring operation.

6. The method according to claim 5, characterized in that, The collection of environmental data around the gantry crane includes: The three-dimensional point cloud data of the environment surrounding the gantry crane is obtained by LiDAR, and the image data of the environment surrounding the gantry crane is obtained by camera device. The three-dimensional point cloud data and the image data are integrated as environmental data for the gantry crane.

7. The method according to claim 5, characterized in that, The calibration of the position between the anchor plate of the gantry crane and the target anchoring pit includes: The longitudinal relative distance between the bottom of the gantry crane and the target anchoring pit, and the lateral relative distance between the anchoring plate and the target anchoring pit are collected. The position of the gantry crane is adjusted based on the longitudinal relative distance and the lateral relative distance until the longitudinal relative distance between the bottom of the gantry crane and the target anchoring pit is less than a first preset threshold, and the lateral relative distance between the anchoring plate and the target anchoring pit is less than a second preset threshold.

8. A computer program product, characterized in that, The computer program product includes computer instructions stored in a computer-readable storage medium and adapted to be read and executed by a processor to cause a computer device having the processor to perform the method as described in any one of claims 5 to 7.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores at least one computer program instruction, which is loaded and executed by a processor to implement the method as described in any one of claims 5 to 7.

10. An electronic device, characterized in that, The electronic device includes one or more processors and one or more memories, wherein at least one piece of program code is stored in the one or more memories, and the at least one piece of program code is loaded and executed by the one or more processors to implement the method as claimed in any one of claims 5 to 7.

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