Container gantry crane spreader automatic centering system and method

Abstract

The application belongs to the hoisting technical field, and particularly relates to a container gantry crane sling automatic centering system and method, which comprises the following steps: a sensor module is arranged on the sling, and is used for collecting position and posture information of the sling and the container in real time; a data processing module receives data transmitted by the sensor module, and performs analysis and calculation; a control module generates a control instruction according to position deviation information of the sling and the container transmitted by the data processing module, and according to a preset control strategy; an executing mechanism is connected with the control module, and the executing mechanism drives the sling to move in X and Y axes in the horizontal direction according to the control instruction sent by the control module, so as to realize centering in left and right directions and front and back directions; lifting of the sling is controlled through a lifting motor, so that the sling is matched with the container in height; the sling is rotated through a rotating motor, so that the angle deviation of the sling is adjusted, and finally accurate centering of the sling and the container is completed.

Description

Technical Field

[0001] This invention belongs to the field of hoisting technology, and particularly relates to an automatic centering system and method for container gantry crane spreaders. Background Technology

[0002] Current Status of Container Shipping: With the rapid development of global trade, container shipping plays a crucial role in cargo transportation. Ports, as key hubs in container shipping, directly impact the speed and cost of the entire logistics chain through their loading and unloading efficiency. Container gantry cranes are among the most important pieces of equipment used in ports for loading and unloading containers, and their operational efficiency and accuracy are critical to port operations.

[0003] The shortcomings of traditional spreader alignment methods: Currently, most container gantry cranes rely primarily on operators to visually observe and manually align the spreader with the container when lifting containers. This method has several problems: First, it requires a high level of experience and skill from the operators, and the varying skill levels among different operators lead to inconsistent alignment accuracy. Second, the manual alignment process is time-consuming, reducing loading and unloading efficiency, especially in busy port environments, which can cause longer waiting times for ships and increase logistics costs. Third, in adverse weather conditions (such as heavy fog or heavy rain), the operator's visibility is severely affected, making it difficult to accurately judge the relative position of the spreader and the container, increasing the risk of collisions, damaging the container and spreader, and even endangering personnel safety. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic centering system for container gantry crane spreaders, which solves the problems of unstable centering accuracy, low loading and unloading efficiency, and poor operational safety under adverse weather conditions that exist in the existing manual centering method. This system enables the spreader to be quickly and accurately aligned with the container, thereby improving the efficiency and safety of container loading and unloading operations in ports.

[0005] To solve the above-mentioned technical problems, the specific technical solution of the present invention is as follows:

[0006] In some embodiments of this application, an automatic centering system and method for container gantry crane spreaders is provided, including:

[0007] The sensor module is mounted on the spreader and is used to collect the position and attitude information of the spreader and the container in real time.

[0008] The data processing module receives data transmitted from the sensor module and performs analysis and calculations.

[0009] The control module generates control commands according to the preset control strategy based on the positional deviation information between the spreader and the container transmitted by the data processing module.

[0010] The actuator is connected to the control module. According to the control commands issued by the control module, the actuator drives the spreader to move horizontally along the X and Y axes to achieve left-right and front-back alignment. The lifting motor controls the lifting of the spreader to match the height of the container. The rotary motor drives the spreader to rotate, adjusting the angular deviation of the spreader, and finally achieving precise alignment between the spreader and the container.

[0011] In some embodiments of this application, the sensor module includes:

[0012] Laser rangefinders are installed at the four corners of the spreader to measure the distance between the spreader and the four corners of the container;

[0013] The vision sensor uses a high-definition camera, which is installed in the center below the spreader to acquire real-time image information of the container;

[0014] The tilt sensor is mounted on the spreader to detect the tilt angle of the spreader.

[0015] In some embodiments of this application, the data processing module analyzes and calculates the distance data measured by the laser rangefinder to determine the horizontal offset between the spreader and the container; it uses an image recognition algorithm to process the image acquired by the vision sensor to identify the container's outline and corner positions, further accurately calculating the positional deviation between the spreader and the container; simultaneously, it combines data from the tilt sensor to correct the spreader's tilt state. The data processing module then transmits the processed data to the control module.

[0016] In some embodiments of this application, the control module generates control commands according to a preset control strategy based on the positional deviation information between the spreader and the container transmitted by the data processing module. The control commands include horizontal movement, lifting, and rotation commands of the spreader to adjust the position and attitude of the spreader and achieve alignment with the container.

[0017] In some embodiments of this application, the actuator consists of a motor, a reducer, a lead screw, and a guide rail, and is connected to the control module.

[0018] Compared with the prior art, the beneficial effects of the present invention are that it improves the alignment accuracy: through the coordinated work of multiple sensors and precise data processing algorithms, the position and attitude information of the spreader and the container can be obtained in real time and accurately, realizing high-precision automatic alignment of the spreader and the container. The alignment accuracy can be controlled within ±5mm, which greatly improves the accuracy of loading and unloading operations.

[0019] Improve loading and unloading efficiency: The automatic alignment system can quickly complete the alignment process between the spreader and the container. Compared with manual alignment, the alignment time can be shortened by more than 50% each time, which significantly improves the loading and unloading efficiency of containers in the port, reduces the time ships spend in the port, and increases the port's throughput capacity.

[0020] Enhanced operational safety: Even in adverse weather conditions, the automatic alignment system remains unaffected by line of sight and can still operate accurately, avoiding collisions caused by limited human visibility and ensuring the safety of personnel, containers, and equipment.

[0021] Reduced labor intensity: It reduces the workload and labor intensity of operators. Operators only need to monitor the system's operating status and do not need to perform tedious manual alignment operations, which improves the comfort and reliability of the operation. Attached Figure Description

[0022] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0023] Figure 1 This is a schematic diagram of motion provided for an embodiment of the present invention;

[0024] Figure 2 This is a schematic diagram of the software interface provided in an embodiment of the present invention. Detailed Implementation

[0025] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0026] To better understand the purpose, structure, and function of this invention, the invention will be described in further detail below with reference to the accompanying drawings.

[0027] Example 1

[0028] According to the embodiments of this application, it includes:

[0029] The sensor module is mounted on the spreader and is used to collect the position and attitude information of the spreader and the container in real time.

[0030] The data processing module receives data transmitted from the sensor module and performs analysis and calculations.

[0031] The control module generates control commands according to the preset control strategy based on the positional deviation information between the spreader and the container transmitted by the data processing module.

[0032] The actuator is connected to the control module. According to the control commands issued by the control module, the actuator drives the spreader to move horizontally along the X and Y axes to achieve left-right and front-back alignment. The lifting motor controls the lifting of the spreader to match the height of the container. The rotary motor drives the spreader to rotate, adjusting the angular deviation of the spreader, and finally achieving precise alignment between the spreader and the container.

[0033] The sensor module includes:

[0034] Laser rangefinders are installed at the four corners of the spreader to measure the distance between the spreader and the four corners of the container;

[0035] The vision sensor uses a high-definition camera, which is installed in the center below the spreader to acquire real-time image information of the container;

[0036] The tilt sensor is mounted on the spreader to detect the tilt angle of the spreader.

[0037] The data processing module analyzes and calculates the distance data measured by the laser rangefinder to determine the horizontal offset between the spreader and the container. It then uses image recognition algorithms to process the images acquired by the vision sensor, identifying the container's outline and corner positions to further accurately calculate the positional deviation between the spreader and the container. Simultaneously, it combines data from the tilt sensor to correct the spreader's tilt. The data processing module then transmits the processed data to the control module.

[0038] Control module: Based on the positional deviation information between the spreader and the container transmitted by the data processing module, the control module generates control commands according to the preset control strategy. The control commands include horizontal movement, lifting and rotating commands of the spreader to adjust the position and attitude of the spreader and achieve alignment with the container.

[0039] Actuator: Composed of a motor, reducer, lead screw, and guide rail, and connected to the control module.

[0040] As the gantry crane approaches the container, the sensor module activates, collecting real-time information about the spreader and the container and transmitting it to the data processing module. The data processing module quickly processes the data and calculates the positional deviation. The control module generates control commands based on this deviation and sends them to the actuator, which then drives the spreader to perform alignment adjustments. During alignment, the sensor module continuously monitors the process, and the data processing and control modules constantly fine-tune the spreader's position based on newly collected data until the spreader and container are precisely aligned. At this point, the control module issues a stop command, and the gantry crane can begin container lifting operations.

[0041] Hardware Selection and Installation: A high-precision laser rangefinder sensor is selected, with a measurement accuracy of ±1mm, and the measurement range meets the operating distance requirements between the spreader and the container. The vision sensor uses a high-definition industrial camera with a resolution of 1920×1080, possessing excellent low-light performance and image stability. The tilt sensor uses a MEMS sensor with an accuracy of ±0.1°. The laser rangefinder sensor is mounted on dedicated brackets at the four corners of the spreader to ensure that the measuring light can be perpendicularly illuminated to the corners of the container. The vision sensor is installed at the center below the spreader to ensure that the top of the container can be completely captured. The tilt sensor is fixed at the center of the spreader to accurately detect the tilt status of the spreader.

[0042] Software programming and debugging: Data processing and control algorithm programs were written in C++. For data processing, functions for laser ranging data processing, image recognition algorithms, and tilt data correction were written. For control, functions for generating control commands and driving actuators were written. Through extensive simulation experiments and actual testing, the algorithm parameters were optimized and adjusted to ensure the system operates accurately and stably.

[0043] System Integration and Testing: The hardware and software are integrated and installed on the container gantry crane. Comprehensive functional testing is conducted, including centering accuracy testing under different working conditions, centering time testing, anti-interference testing, and simulated testing under adverse weather conditions. Based on the test results, the system is further optimized and improved to ensure it meets the needs of actual port operations. Practical application verification shows that the automatic centering system for container gantry crane spreaders of this invention can effectively improve loading and unloading efficiency and safety, and has good application and promotion value.

[0044] In the description of this application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0045] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0046] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0047] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0048] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An automatic centering system for container gantry crane spreaders, characterized in that, include: The sensor module is mounted on the spreader and is used to collect the position and attitude information of the spreader and the container in real time. The data processing module receives data transmitted from the sensor module and performs analysis and calculations. The control module generates control commands according to the preset control strategy based on the positional deviation information between the spreader and the container transmitted by the data processing module. The actuator is connected to the control module. According to the control commands issued by the control module, the actuator drives the spreader to move horizontally along the X and Y axes to achieve left-right and front-back alignment. The lifting motor controls the lifting of the spreader to match the height of the container. The rotary motor drives the spreader to rotate, adjusting the angular deviation of the spreader, and finally achieving precise alignment between the spreader and the container.

2. The automatic centering system for container gantry crane spreaders according to claim 1, characterized in that, The sensor module includes: Laser rangefinders are installed at the four corners of the spreader to measure the distance between the spreader and the four corners of the container; The vision sensor uses a high-definition camera, which is installed in the center below the spreader to acquire real-time image information of the container; The tilt sensor is mounted on the spreader to detect the tilt angle of the spreader.

3. The automatic centering system for container gantry crane spreaders according to claim 1, characterized in that, The data processing module analyzes and calculates the distance data measured by the laser rangefinder to determine the horizontal offset between the spreader and the container. It then uses an image recognition algorithm to process the image acquired by the vision sensor, identifying the container's outline and corner positions to further accurately calculate the positional deviation between the spreader and the container. Simultaneously, it combines data from the tilt sensor to correct the spreader's tilt. The data processing module then transmits the processed data to the control module.

4. The automatic centering system for container gantry crane spreaders according to claim 1, characterized in that, The control module generates control commands according to a preset control strategy based on the positional deviation information between the spreader and the container transmitted by the data processing module. The control commands include horizontal movement, lifting, and rotation commands of the spreader to adjust the position and attitude of the spreader and achieve alignment with the container.

5. The automatic centering system for container gantry crane spreaders according to claim 1, characterized in that, The actuator consists of a motor, a reducer, a lead screw, and a guide rail, and is connected to the control module.

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