Intelligent prevention and control device for empty and heavy mixed loading of gantry crane

Abstract

The utility model provides an intelligent prevention and control device for empty and heavy mixed loading of a gantry crane, which belongs to the field of gantry crane devices and comprises the gantry crane, an industrial personal computer, a relay IO (input / output) module, a wireless circuit closer, a trolley position sensor, a gantry crane lifting appliance unlocking and locking lock, a gantry crane lifting appliance 20 / 40 foot lock, a camera and an electronic scale. The relay IO module is respectively connected with the wireless circuit closer, the door crane lifting appliance unlocking and locking lock, the door crane lifting appliance 20 / 40 foot lock and the electronic scale, and the wireless circuit closer is respectively connected with the camera and the trolley position sensor. The prevention and control device effectively prevents empty boxes and heavy boxes from being loaded in the same vehicle in a mixed mode, and potential safety hazards are eliminated. The prevention and control device provided by the utility model can automatically complete vehicle number identification and container weight judgment, effectively prevents mixed loading of empty containers and heavy containers in the same vehicle, reduces the time and labor cost of manual inspection, accelerates the speed of loading and unloading operation, and eliminates potential safety hazards.

Description

Technical Field

[0001] The utility model relates to the field of gantry crane devices, in particular to an intelligent prevention and control device for empty and heavy mixed loading of gantry cranes. Background Art

[0002] At present, in terms of the safe use of gantry cranes, each freight station has installed relevant safety control measures based on the key links in the operation. However, the equipment and facilities of gantry cranes in railway freight yards are inherently insufficient and limited. Although there are certain technical prevention measures, they mostly adopt a model of human defense as the main and technical defense as the auxiliary. They still rely mainly on the judgment and operation of the driver. They have not yet escaped the situation of requiring a lot of manpower to monitor and control, and the effect of reducing costs and increasing efficiency is not obvious. There are safety hazards for teams that fail to implement operating standards.

[0003] The safety and control technologies currently used in gantry cranes primarily include inching lifting devices, measures to prevent empty and heavy container loading, electronic scales, and video surveillance. The inching lifting device uses a PLC controller to achieve short-distance lifting, preventing containers from becoming entangled with the vehicle body and potentially causing derailment. Measures to prevent empty and heavy container loading include an empty-load switch on the electronic scale to differentiate between empty and loaded containers. Electronic scales are divided into container spreader scales and gantry crane hook scales, which weigh containers and bulk cargo, respectively, with weights accumulated manually. Video surveillance records gantry crane operations, primarily for subsequent analysis.

[0004] The shortcomings of existing technologies are mainly reflected in the high reliance on manual operation to determine container weight, which leads to low efficiency and prone to errors; the low degree of automation in on-site operations makes it difficult for existing manual operation methods to ensure high efficiency and accuracy when faced with a large number of operational demands; the lack of intelligent recognition makes it impossible to automatically obtain and determine key information during the container loading process; in addition, the reliance on manual labor and multiple sets of independent safety devices leads to a large consumption of manpower and resources, increasing overall operating costs. Utility Model Content

[0005] The purpose of this utility model is to provide an intelligent prevention and control device for mixed loading of empty and loaded containers during gantry crane operations, solving the technical problem of mixed loading of empty and loaded containers during existing gantry crane operations. This device automatically obtains the vehicle number of the operating vehicle and monitors the weight of the container in real time, effectively preventing the mixed loading of empty and loaded containers, improving the efficiency and safety of loading and unloading operations, and avoiding accidents caused by mixed loading of empty and loaded containers.

[0006] In order to achieve the above purpose, the technical solution adopted by the present utility model is as follows:

[0007] An intelligent prevention and control device for mixed loading of empty and heavy gantry cranes includes a gantry crane, an industrial computer, a relay IO module, a wireless connector, a trolley position sensor, a gantry crane spreader lock, a 20 / 40 foot lock for the gantry crane spreader, a camera, and an electronic scale. The industrial computer is connected to the relay IO module, which is respectively connected to the wireless connector, the gantry crane spreader lock, the 20 / 40 foot lock for the gantry crane spreader, and the electronic scale. The wireless connector is respectively connected to the camera and the trolley position sensor.

[0008] Furthermore, the industrial computer is connected to an alarm, which is installed in the driver's cab.

[0009] Furthermore, a 20 / 40 foot lock for the gantry crane is provided on the operator's cab console.

[0010] Furthermore, a trolley position sensor is installed on the main beam of the gantry crane, and the trolley position sensor obtains the position of the gantry crane trolley.

[0011] Furthermore, the camera takes a picture of the carriage and extracts the vehicle number.

[0012] Furthermore, an electronic scale weighs the lifted container.

[0013] The utility model has the following beneficial effects due to the adoption of the above technical solution:

[0014] 1. The prevention and control device provided in the present invention effectively prevents empty boxes and loaded boxes from being mixed in the same vehicle, eliminating potential safety hazards.

[0015] 2. The prevention and control device provided in the present invention can automatically complete vehicle number recognition and box weight judgment, reducing the time and labor cost of manual inspection and speeding up the loading and unloading operations.

[0016] 3. The prevention and control device provided in the present invention reduces the cost consumption caused by incorrect loading and unloading.

[0017] 4. The prevention and control device provided in the present invention simplifies the operation process through an automated identification and judgment mechanism, making the entire loading and unloading process smoother and more efficient. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a block diagram of the utility model prevention and control device;

[0019] Figure 2 It is a schematic diagram of the process of empty and heavy box judgment of the utility model;

[0020] Figure 3 It is a schematic diagram of the process of triggering a camera to take photos in the utility model. DETAILED DESCRIPTION

[0021] To make the objectives, technical solutions, and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and preferred embodiments. However, it should be noted that many of the details listed in this specification are merely provided to help readers gain a thorough understanding of one or more aspects of the present invention, and these aspects of the present invention can be implemented even without these specific details.

[0022] like Figure 1 As shown, an intelligent prevention and control device for mixed loading of empty and loaded containers on a gantry crane includes a gantry crane, an industrial computer, a relay I / O module, a wireless access panel, a trolley position sensor, a gantry crane spreader lock, a 20 / 40-inch lock for the gantry crane spreader, a camera, and an electronic scale. The industrial computer is connected to the relay I / O module, which is in turn connected to the wireless access panel, the gantry crane spreader lock, the 20 / 40-inch lock for the gantry crane spreader, and the electronic scale. The gantry crane spreader lock / open signal is used as a means of determining whether a container loading operation is effective (an open lock indicates that the spreader is not equipped with a container, while a closed lock indicates that the spreader is equipped with a container). The wireless access panel is connected to the camera and the trolley position sensor. The industrial computer is connected to an alarm installed in the driver's cab. The alarm is used to sound an alarm when mixed loading of empty and loaded containers occurs. If the device detects mixed loading of empty and loaded containers, the alarm sounds an alarm signal. The industrial computer processes images captured by the camera and extracts the vehicle number. The industrial computer also processes various signals transmitted by the relay I / O module and makes judgments. The 20 / 40-foot lock for the gantry crane spreader is installed on the operator's cab console. The 20 / 40-foot lock signal of the gantry crane spreader is used to determine the container type (20-foot containers require empty and heavy mixed loading control, while 40-foot containers do not require control). The 20 / 40-foot switch signal on the operator's cab console is introduced to determine whether the spreader is in the 20-foot state, thereby reducing the number of non-operating containers. The control device set in this utility model can automatically complete vehicle number recognition and container weight judgment, reducing the time and labor cost of manual inspection and speeding up the loading and unloading operation.

[0023] like Figure 2 As shown, for two 20-foot containers hoisted on the same vehicle, the device records their weights separately and compares them. If the weight difference between the two containers is less than 3 tons (2.0-2.8 tons for an empty container and 20-28 tons for a loaded container), they are considered both empty or loaded, meeting the loading requirements. By correlating the acquired vehicle number information with the corresponding container weight data, the weight of each container is accurately matched to the vehicle it is loaded on.

[0024] When the same vehicle is lifting two 20-foot containers, the weights of the left and right containers must be recorded separately, and the weight difference determined. If the weight difference is less than 3 tons, the container is considered to meet the loading requirements. For 40-inch containers, the 20 / 40-foot switch signal on the operator's cab console is used to determine whether the spreader is in the 20-foot state, eliminating interference from the loading of a single 40-foot container. The result is output and an alarm is generated, matching the identified vehicle number with the corresponding container weight to determine whether mixed empty and heavy loading occurs. If mixed empty and heavy loading is detected, the industrial computer transmits this information to the alarm, which sounds an alarm and prompts the operator to take action.

[0025] like Figure 3 As shown, the trolley position sensor is installed on the gantry crane's main beam. This sensor detects the position of the gantry crane's trolley. Because gantry cranes operate in a variety of ways, this signal serves as a tool for determining whether container loading is effective. When a gantry crane is loading a container, the gantry crane's trolley travels above the railway line, the spreader hoisting the container, and the lifting mechanism slowly lowers the lifted container onto the carriage. This triggers the trolley position sensor, which is fixed to the gantry crane's main beam. The trolley position sensor wirelessly transmits a signal to the relay I / O module. Simultaneously, the signal indicating the spreader has switched to a locked state is transmitted to the relay I / O module. This signal is then transmitted to the industrial computer via the relay I / O module for processing and analysis.

[0026] The camera takes a picture of the carriage to extract the vehicle number. This uniquely identifies the loaded carriage, enabling intelligent identification of the weight of the container loaded into the vehicle during loading operations. A specific trigger signal is set to capture the vehicle number image only when needed. The spreader's open / close signal is introduced to ensure that only after the container is loaded does the industrial computer issue a capture command to the camera, triggering the camera to take a photo. The camera then transmits the photo via a wireless interface to the relay I / O module, which then transmits it to the industrial computer. The industrial computer then identifies the vehicle number based on the photo and outputs the result for storage, enabling automatic capture and recognition of the vehicle number image during container lifting.

[0027] The electronic scale weighs the lifted container to obtain the container weight. To confirm a complete and effective operation, the industrial computer saves the container weight data from the proximity switch signal when the gantry crane trolley is in place to the unlocking signal, and takes the maximum value in this time period as the container weight value.

[0028] How it works

[0029] First, when the gantry crane is lifting a container, the gantry crane trolley runs above the railway line, the spreader is lifting the container, and the lifting mechanism slowly drops the lifted container into the carriage. At this time, the trolley position sensor installed at a fixed position on the gantry crane main beam will be triggered. The trolley position sensor transmits the signal wirelessly to the relay IO module, and at the same time, the spreader rotation lock is locked. The signal is transmitted to the relay IO module, and then transmitted to the industrial computer by the relay IO module, and then processed and analyzed by the industrial computer; if the two signals are established, the industrial computer instructs the camera to take a picture of the carriage to identify the vehicle number, and the signal is also input to the relay IO module through the wireless receiver, and then input to the industrial computer through the relay IO module for vehicle number identification and extraction; if the trolley position sensor signal and the spreader rotation lock locking signal are not received completely, the camera photo function will not be started, and at the same time, the gantry crane electronic scale sensor will weigh the lifted container in real time. Second, after obtaining the carriage number (the process from taking a photo to successfully extracting the carriage number is completed within 3 seconds), the spreader and container are still slowly descending, and the trolley position sensor signal is continuously received and the spreader lock is detected to be in the locked state signal. The device records the weight information of the container (the weight signal is input from the electronic scale controller to the relay IO module, and then input to the industrial computer through the relay IO module). Third, a second confirmation is continuously performed. The trolley position sensor signal is received and the spreader lock is detected to change from the locked state to the unlocked state signal. At the same time, it is detected that the spreader is in the 20-foot container control mode (the same control signal is input to the relay IO module, and then input to the industrial computer through the relay IO module). The device confirms that it is a valid loading (that is, it confirms that the container has been loaded into the train carriage). All signals will be summarized and sent to the industrial computer for judgment. If the trolley position sensor or the unlocking and closing signals are missing, or if the spreader is detected to be in the 40-foot container control mode, the device will judge it as an invalid loading (recorded as invalid information and no subsequent judgment will be made). Fourth, the device continuously repeats the detection and discrimination work according to the above set conditions. The weight of the same vehicle number will be recorded together and then compared. If the weight difference exceeds 3 tons, an alarm will be sounded through the external alarm installed in the driver's cab. (Empty box is about 3 tons, loaded box is 30 tons or more, general overload is 10-15 tons, and severe overload is 15 tons or more)

[0030] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. An intelligent control device for gantry crane empty and mixed loading, characterized by: It includes a door crane, an industrial computer, a relay IO module, a wireless connector, a trolley position sensor, a door crane lock, a door crane 20 / 40 foot lock, a camera and an electronic scale. The industrial computer is connected to the relay IO module, and the relay IO module is respectively connected to the wireless connector, the door crane lock, the door crane 20 / 40 foot lock and the electronic scale. The wireless connector is respectively connected to the camera and the trolley position sensor.

2. The intelligent control device for empty and mixed loading of gantry cranes according to claim 1 is characterized by: The industrial computer is connected to an alarm, which is installed in the driver's cab.

3. The intelligent control device for empty and mixed loading of gantry cranes according to claim 1 is characterized by: The 20 / 40 foot lock of the gantry crane is set on the operating table in the driver's cab.

4. The intelligent control device for empty and mixed loading of gantry cranes according to claim 1 is characterized in that: The trolley position sensor is installed on the main beam of the gantry crane, and the trolley position sensor obtains the position of the gantry crane trolley.

5. The intelligent control device for empty and mixed loading of gantry cranes according to claim 1 is characterized in that: The camera takes a picture of the carriage and extracts the vehicle number.

6. The intelligent control device for empty and mixed loading of gantry cranes according to claim 1 is characterized by: Electronic scales weigh the lifted containers.

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