Radar anti-collision intelligent control system for electromagnetic hanging beam of bridge crane

Abstract

The utility model belongs to the technical field of crane equipment, and provides a bridge crane electromagnetic hanging beam radar anti-collision intelligent control system which comprises millimeter-wave radars, a wireless data transmission module radio station, a radar controller and a PLC (programmable logic controller), and the millimeter-wave radars are mounted at four corners of an electromagnetic hanging beam; the four wireless data transmission module radio stations I are mounted in a switch box in the middle of the electromagnetic lifting beam and are wirelessly connected with the wireless data transmission module radio stations II in a cab; the radar controller is arranged in a cab, a USB interface is arranged on a main control board in a shell of the radar controller, the USB interface is connected with a CPU, the CPU is connected with a 40PIN GPIO male connector on the main control board, and the 40PIN GPIO male connector is connected with a 40PIN GPIO female connector on a relay module board. According to the utility model, high-speed signal transmission can be realized without placing a control cable or a network cable for a long distance, collision between an electromagnetic hanging beam of a travelling crane and lower-layer equipment as well as between a cart and a transport vehicle is avoided, tedious wiring is avoided, and the production cost is reduced.

Description

Technical Field

[0001] The utility model belongs to the technical field of crane equipment, in particular to an electromagnetic hanging beam radar anti-collision intelligent control system for a bridge crane. Background Art

[0002] The electromagnetic crane has a large lifting beam area and requires a large space when traveling, which further increases the risk of collision between the electromagnetic lifting beam and the semi-gantry crane. Similarly, the transportation volume of the gantry crane at the terminal has increased, and the intensive operation at the terminal has become more intensive. The collision probability between some gantry cranes and transport vehicles has also increased.

[0003] Related reference CN114408757A discloses a collision avoidance system for a crane travel mechanism, comprising a millimeter-wave radar sensor for detecting obstacles arranged outside the travel mechanism, a mounting structure for protecting the sensor, and an collision avoidance system control box arranged on the crane. A PLC controller electrically connected to the millimeter-wave radar sensor is arranged in the control box. However, the millimeter-wave radar sensor is connected to the PLC controller in the collision avoidance system control box via a communication cable, which belongs to wired transmission, and the wiring is cumbersome and requires a lot of manpower and material resources. Utility Model Content

[0004] The technical problem to be solved by the utility model is to provide a radar anti-collision intelligent control system for the electromagnetic lifting beam of a bridge crane, which can avoid collisions between the electromagnetic lifting beam of the vehicle and the lower equipment, the large car and the transport vehicle, while eliminating a large amount of manpower and material resources used for wiring and reducing production costs.

[0005] In order to solve the above technical problems, the utility model provides a radar anti-collision intelligent control system for the electromagnetic beam of a bridge crane, including a millimeter-wave radar, a wireless digital transmission analog radio station I, a wireless digital transmission analog radio station II, a radar controller and a PLC. The millimeter-wave radar is installed at the four corners of the electromagnetic beam, and emits and collects signals at a radiation angle of 120 degrees in the horizontal direction and 30 degrees in the vertical direction; the millimeter-wave radar transmits a 485 signal to each wireless digital transmission analog radio station I, there are four wireless digital transmission analog radio stations I, which are installed in a switch box in the middle of the electromagnetic beam, and the four wireless digital transmission analog radio stations I and the wireless digital transmission analog radio stations II are wirelessly connected; the four wireless digital transmission analog radio stations I wirelessly transmit the signal to the wireless digital transmission analog radio station II for reception. The wireless digital transmission analog radio II is installed in the cab; the wireless digital transmission analog radio II transmits the 485 signal to the radar controller after receiving it; the radar controller is installed in the cab; a main control board is arranged in the shell of the radar controller, a USB interface is arranged on the main control board, the USB interface is connected to the CPU, the CPU is connected with eight 40PIN GPIO male connectors, the 40PIN GPIO male connector is connected to the 40PIN GPIO female connector, the 40PIN GPIO female connector is installed on the relay module board, the main control board sets eight-way relays through the 40PIN GPIO female connector on the relay module board, and one 40PIN GPIO female connector controls one relay; optical coupling isolation is adopted between the relays.

[0006] By adopting the above technical solution, the millimeter-wave radar is installed at the four corners of the electromagnetic hoist beam. The millimeter-wave radar transmits the detected obstacle information through wireless digital transmission analog radio I and wireless digital transmission analog radio II. It can transmit signals at high speed without placing control cables or network cables over long distances, and the transmission distance can reach 2,500 meters, avoiding collisions between the electromagnetic hoist beam and the lower equipment, the gantry machine's cart and the transport vehicle, while eliminating the cumbersome wiring, reducing the large amount of manpower and material resources used for wiring, and reducing production costs.

[0007] Preferably, each millimeter-wave radar is connected to its own wireless digital transmission analog radio station I through a 485 signal line; the wireless digital transmission analog radio station II is connected to the USB interface on the main control board through a 485 signal line.

[0008] By adopting the above technical solutions, the connection between the millimeter wave radar and the wireless digital transmission analog radio station I, the wireless digital transmission analog radio station II and the USB interface is reliable and the operation is stable.

[0009] Preferably, the main control board of the radar controller is also provided with an HDMI interface, an output terminal block, and an SD card slot. A flat panel display is provided on the HDMI interface; and the output terminal block is connected to the input end of the PLC.

[0010] By adopting the above technical solution, the PLC controls the deceleration and stopping of the trolley in the east-west direction and the deceleration and stopping of the trolley in the north-south direction through the relay signals of the eight relays output by the output terminal block, and realizes the linkage control of the crane in multiple directions according to the millimeter-wave radar signal.

[0011] Preferably, an SD card is inserted into the SD card slot, and the software program is stored in the SD card.

[0012] By adopting the above technical solutions, the radar controller integrates hardware and software, does not need to add a host computer, is smaller in size and cheaper in price, and reduces production costs.

[0013] Compared with the prior art, the beneficial effects of the present invention are:

[0014] 1. The millimeter-wave radar of the utility model is installed at the four corners of the electromagnetic suspension beam. The millimeter-wave radar transmits the detected obstacle information through the wireless digital transmission analog radio station I and the wireless digital transmission analog radio station II. It can transmit signals at high speed without placing control cables or network cables over long distances, and the transmission distance can reach 2,500 meters. It avoids collisions between moving trucks and transport vehicles, eliminates the cumbersome wiring, reduces a large amount of manpower and material resources used for wiring, and reduces production costs.

[0015] 2. The utility model PLC controls the deceleration and stopping of the trolley in the east-west direction and the deceleration and stopping of the trolley in the north-south direction through the relay signals of eight relays output by the output terminal block, and realizes the linkage control of the crane in multiple directions according to the millimeter wave radar signal.

[0016] 3. The utility model inserts an SD card into the SD card slot of the main control board, and the SD card stores the software program, so that the radar controller integrates hardware and software, does not need to add a host computer, is smaller in size and cheaper in price, and reduces production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a system flow chart of the utility model.

[0018] Figure 2 This is a radar controller of the utility model.

[0019] Figure 3 This is an application scenario diagram of the utility model.

[0020] Figure 4 This is the installation position diagram of the millimeter wave radar of the utility model.

[0021] Figure number: 1. 40PIN GPIO interface, 2. millimeter wave radar, 3. USB interface, 4. radar controller, 5. SD card slot, 6. HDMI interface, 7. electromagnetic lifting beam, 8. power interface, 9. main control board, 11. relay, 12. output terminal block. DETAILED DESCRIPTION

[0022] To further deepen our understanding, Figure 3 In the application scenario of the electromagnetic crane anti-collision system shown in the figure, the electromagnetic crane is located on the upper track of the workshop, and the lower track is composed of multiple half-door electric hoist cranes. The passage between the half-door cranes is narrow and can only pass the electromagnetic crane beam 7, so the possibility of collision is relatively high.

[0023] Depend on Figure 4 As shown, the millimeter wave radar 2, model REA-1010, is installed at the four corners of the electromagnetic hanging beam 7. The installation position of the millimeter wave radar 2 is shown in the figure. It emits 120° horizontal × 30° pitch 20 meters of millimeter wave detection obstacles, the operating frequency is 81GHz, and FMCW (frequency modulated continuous wave) is used for detection. The millimeter wave radar 2 establishes a relative tracking track for the lower half-door crane and equipment, and sends an alarm signal after the object enters the alarm area. The alarm and warning of each millimeter wave radar 2 correspond to a relay 11 respectively, and there are a total of 4 millimeter wave radars 2 and eight relay signals.

[0024] Each millimeter wave radar 2 is connected to a wireless digital transmission analog radio station I through two 485 signal lines, and at the same time, the 485 signal is wirelessly transmitted to the wireless digital transmission analog radio station II in the cab through the wireless digital transmission analog radio station I installed in the switch box of the electromagnetic suspension beam 7. Both the wireless digital transmission analog radio station I and the wireless digital transmission analog radio station II use the A100-F433M20 industrial-grade wireless digital transmission analog radio station. The four wireless digital transmission analog radio stations I are wirelessly connected to the wireless digital transmission analog radio station II through antennas. The wireless digital transmission analog radio station II is connected to the USB interface 3 (3.0 x 2) of the radar controller 4 through a 485 signal line. The millimeter wave radar 2 of the present application is installed at the four corners of the electromagnetic suspension beam. The millimeter wave radar 2 transmits the detected obstacle information through the wireless digital transmission analog radio station I and the wireless digital transmission analog radio station II. It can transmit signals at high speed without placing control cables or network cables over long distances, and the transmission distance can reach 2,500 meters. While avoiding collisions between driving trucks and transport vehicles, it eliminates the cumbersome wiring, reduces a large amount of manpower and material resources used for wiring, and reduces production costs. The radar controller 4 of the present application is more flexible in connection with the original crane control system, and the 485 signal can also be wirelessly transmitted to the radar controller 4 through the wireless digital transmission analog radio II, and the PLC of the original system can be directly controlled through the output relay 11 signal of the radar controller 4, and the PLC and the participating cranes can be controlled to decelerate and stop running. The present application can also be used for the trolley anti-collision of the portal machine, and can solve the problem of the cables and network cables being twisted and entangled when the cables and network cables cannot pass through the portal machine and the portal machine continuously rotates.

[0025] The wireless digital transmission analog radio II in the cab transmits the received 485 signal to the radar controller 4 through the 485 to USB converter. After receiving the signal, the radar controller 4 determines which direction the millimeter wave radar 2 detects the obstacle through the program, and outputs the relay 11 signal, and at the same time displays the warning or alarm direction on the display screen animation. The radar controller 4 outputs the relay 11 signal to the PLC. On the one hand, the PLC triggers the alarm to issue an audible and visual alarm according to the relay signal, and on the other hand, controls the deceleration or stop of the running direction of the large and small vehicles of the bridge crane according to the corresponding relay signal. After the obstacle is removed and the warning and alarm signals of the millimeter wave radar 2 are eliminated, the operation is resumed. It effectively plays the role of obstacle avoidance and ensures the safe operation of the production process.

[0026] The radar controller 4 uses an ARM-based main control board with a main frequency of 2.4GHz, a quad-core 64-bit Arm Cortex-A76, and is loaded with a desktop version of the Linux operating system, which is easy to operate. It is equipped with 2GB of memory and 32GB of large-capacity storage. It has a variety of external interfaces, such as a USB interface 3 (supporting 5Gbps simultaneous operation), a video interface HDMI interface 6, an SD card slot 5, a wireless network card, Bluetooth 5.0, and a 40PIN GPIO interface 1. It can connect to a video display, a mouse, a keyboard, and other peripherals, and can control relays through GPIO.

[0027] The radar controller 4 is installed in the cab, and a main control board 9 is arranged in the shell of the radar controller 4. The main control board 9 is provided with a USB interface 3, which is connected to the CPU, and the CPU is connected to eight 40PIN GPIO male connectors, and the eight 40PIN GPIO male connectors are connected to eight 40PIN GPIO female connectors 1 on the relay module board. The main control board 9 is provided with eight relays 11 through the relay module board, and the 40PIN GPIO female connector 1 is connected to the relay module board. One 40PIN GPIO female connector 1 controls one relay 11, and each relay 11 is equipped with a 40PIN GPIO male connector. Each relay 11 has two contact modes, one normally open and one normally closed. The trigger signal is 3.3V / 5V, and the closing current is 6mA (each way). The load is allowed to be connected to ≤5A 250V AC or ≤5A 30V DC. Optical coupling isolation is used between the relays 11 to avoid interference from high-voltage circuits. At the same time, it is equipped with an indicator light, which can easily check the working status of the relay. The wireless digital transmission analog radio II in the cab transmits the signal from the USB interface 3 to the radar controller 4 through two 485 signal lines and a 485 to USB converter. Figure 1The main control board 9 of the radar controller 4 is also provided with an HDMI interface 6, an output terminal block 12, an SD card slot 5 and a power interface 8. The software program is stored in the SD card of the controller, and the SD card is inserted in the SD card slot 5, so that the radar controller 4 integrates hardware and software, does not need to add a host computer, is smaller in size and cheaper in price, and reduces production costs.

[0028] The radar controller 4 is connected to a 5V power supply through the power interface 8, and the output terminal block 12 is connected to the input end of the PLC. The PLC controls the deceleration and stop of the trolley in the east-west direction and the deceleration and stop of the trolley in the north-south direction through the relay signals of the eight relays output by the output terminal block 12, and realizes the linkage control of the crane in multiple directions according to the signal of the millimeter wave radar 2. In the workplace where the vehicles are densely layered, the equipment is densely high-end and the passages are narrow, or when the personnel drive fatigued for a long time, it plays a full-scale monitoring role and can control the equipment to automatically avoid obstacles, prevent the electromagnetic hanging beam 7 from colliding with other vehicles and high-end equipment due to the large space occupied, avoid major equipment damage and casualties, and ensure safe production. At the same time, the HDMI interface 6 is connected to the flat-panel display, the display and the radar controller 4 are installed in a switch box, and the display is installed in front of the shell of the radar controller 4. The display shows a simulation diagram of the electromagnetic hanger beam 7, and dynamically displays the obstacles around the electromagnetic hanger beam and responds to early warning and alarm information. The distance between the four corners of the electromagnetic hanger beam 7 and the obstacles can be intuitively seen from the display screen. When the millimeter-wave radar 2 issues a warning, a yellow ripple signal is displayed, and when the millimeter-wave radar 2 alarms, a red ripple signal is displayed.

[0029] When working, the four millimeter wave radars 2 installed at the four corners of the electromagnetic suspension beam 7 convert the early warning and alarm signals into 485 signals and transmit them to four wireless digital transmission analog radios A100-F433M20. The digital transmission analog radio is installed in the middle switch box of the electromagnetic suspension beam 7 and has the functions of fixed-point transmission, transparent transmission and air wake-up. The receiving sensitivity is as high as -121dBm@2.0k and the transmission distance is 2500 meters. The four wireless digital transmission analog radios I transmit the signals wirelessly to the wireless digital transmission analog radio II installed in the cab for reception. After receiving the signals, the wireless digital transmission analog radio II transmits the signals to the radar controller 4. The radar controller 4 receives the corresponding signals and controls the relays CH1~CH8 (such as Figure 1 ) action, CH1~CH8 action transmits the normally open signal of relay 11 to PLC. No matter which angle direction there is an obstacle signal, a relay signal is output to trigger the alarm to sound.

[0030] At the same time, according to the different actions of CH1~CH8 relay 11, PLC outputs relay 11 signal to control the deceleration and stopping of the driving trolley in the east-west direction and the trolley in the north-south direction. For example: when the driver operates the driving trolley to drive eastward and the trolley to drive northward at the same time, the northeast corner millimeter-wave radar 2 detects an obstacle. At this time, the millimeter-wave radar 2 scanning distance is set to 5 meters for early warning and 2 meters for alarm. When the electromagnetic lifting beam 7 reaches 5 meters away from the northeast obstacle, the cab alarm sounds an alarm, and the trolley slows down to the east and the trolley slows down to the north. When it reaches 2 meters from the northeast obstacle, the cab alarm continues to sound an alarm, and the trolley stops to the east and the trolley stops to the north. When the obstacle is removed and the early warning and alarm signals of the millimeter-wave radar 2 are eliminated, operation is resumed.

[0031] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are only examples and do not limit the present invention. The purpose of the present invention has been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments. Without departing from the principles, the embodiments of the present invention may be deformed or modified in any way.

Claims

1. A bridge crane electromagnetic beam radar anti-collision intelligent control system, comprising a millimeter wave radar (2), characterized in that: The invention also comprises a wireless digital transmission analog radio station I, a wireless digital transmission analog radio station II, a radar controller (4) and a PLC, wherein the millimeter wave radar (2) is installed at the four corners of the electromagnetic suspension beam (7); the wireless digital transmission analog radio station I is four, which are installed in a switch box in the middle of the electromagnetic suspension beam (7), and the four wireless digital transmission analog radio stations I are wirelessly connected to the wireless digital transmission analog radio station II; the wireless digital transmission analog radio station II is installed in the cab; the radar controller (4) is installed in the cab; a main control board (9) is arranged in the shell of the radar controller (4), and a USB interface (3) is arranged on the main control board (9), and the USB interface (3) is connected to the CPU, and the CPU output is connected to eight 40PIN GPIO interfaces (1), and the 40PIN GPIO male connector is connected to the 40PIN GPIO female connector, and the 40PIN GPIO female connector is installed on the relay module board, and one 40PIN GPIO female connector controls one relay (11).

2. According to the electromagnetic beam radar anti-collision intelligent control system of bridge crane according to claim 1, it is characterized by: Each millimeter wave radar (2) is connected to its own wireless digital transmission analog radio station I through a 485 signal line; the wireless digital transmission analog radio station II is connected to the USB interface (3) through a 485 signal line.

3. According to the electromagnetic beam radar anti-collision intelligent control system of bridge crane according to claim 1, it is characterized by: The main control board (9) of the radar controller (4) is also provided with an HDMI interface (6), an output terminal block (12) and an SD card slot (5); a flat panel display is provided on the HDMI interface (6); and the output terminal block (12) is connected to an input end of a PLC.

4. According to the electromagnetic beam radar anti-collision intelligent control system of bridge crane according to claim 3, it is characterized by: An SD card is inserted into the SD card slot (5), and the SD card stores software programs.

Images