Gantry crane full bucket detection system
Through the combination of encoders, pressure detection and camera modules, the output power of the gantry crane can be dynamically adjusted, solving the problem of traditional gantry crane operation relying on manual experience and achieving efficient and safe bucket status detection and control.
Patent Information
- Application Number
- CN202422833743.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-20
- Publication Date
- 2025-09-05
- Estimated Expiration
- 2034-11-20
AI Technical Summary
Traditional gantry crane operations rely on operator experience, resulting in low efficiency and prone to misjudgment, affecting operational efficiency and equipment life.
An encoder is used to detect the bucket depth, a pressure detection module monitors the hydraulic cylinder pressure, and a camera module is used to detect the load capacity. The main control module analyzes and determines, and the power regulation module dynamically adjusts the gantry crane output power. The photovoltaic power generation module and power management system are used to ensure stable system operation.
It achieves precise control of the bucket status, improves the working efficiency of the gantry crane, reduces energy consumption and operating costs, and ensures the safety and stability of operations.
Smart Images
Figure CN223304044U_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to the field of door crane detection technology, and in particular to a door crane full bucket detection system. Background Art
[0002] In port operations, gantry cranes (also known as portal cranes) are key equipment, responsible for loading and unloading cargo, particularly bulk cargo such as coal and ore. Accurately determining the load status of the gantry crane's bucket (particularly whether it is full) during excavation and loading is crucial for improving operational efficiency, reducing energy consumption, and ensuring equipment safety. However, traditional gantry crane operation often relies on the operator's experience and intuitive judgment. This approach is not only inefficient but also prone to overloading or underloading due to misjudgment, which in turn affects operational efficiency and equipment life. Utility Model Content
[0003] The disclosed embodiment provides a portal crane full bucket detection system to solve the problem of low operating efficiency of traditional portal cranes.
[0004] The embodiment of the present disclosure provides a door crane full bucket detection system, comprising: an encoder, a pressure detection module, a main control module and a power regulation module;
[0005] The encoder, the pressure detection module and the power regulation module are all connected to the main control module;
[0006] The encoder is configured to detect the excavation depth of the bucket, the pressure detection module is configured to detect the pressure of the hydraulic cylinder of the portal crane, and the power adjustment module is configured to adjust the output power of the portal crane.
[0007] In an exemplary embodiment of the present disclosure, it further includes: a camera module;
[0008] The camera module is connected to the main control module;
[0009] The camera module is configured to detect the loading amount of the gantry crane bucket.
[0010] In an exemplary embodiment of the present disclosure, it further includes: a fill light module;
[0011] The fill light module is connected to the main control module;
[0012] The fill light module is configured to provide fill light for the camera module.
[0013] In an exemplary embodiment of the present disclosure, it further includes: a light intensity detection module;
[0014] The light intensity detection module is connected to the main control module;
[0015] The light intensity detection module is configured to detect the light intensity of the door crane working environment.
[0016] In an exemplary embodiment of the present disclosure, it further includes: a photovoltaic power generation module;
[0017] The photovoltaic power generation module is used to convert light energy into electrical energy, and the photovoltaic power generation module is configured to provide working power to the door crane full bucket detection system.
[0018] In an exemplary embodiment of the present disclosure, it further includes:
[0019] Power switching module and battery;
[0020] The control end of the power switching module is connected to the main control module, the first end of the power switching module is connected to the photovoltaic power generation module, and the second end of the power switching module is connected to the battery.
[0021] In an exemplary embodiment of the present disclosure, the device further includes: a charging control module and a discharging control module;
[0022] The first end of the charging control module is connected to the photovoltaic power generation module, and the second end of the charging control module is connected to the battery;
[0023] The first end of the discharge control module is connected to the battery, and the second end of the discharge control module is used to output the door crane full bucket detection system to provide working power.
[0024] The beneficial effects of the gantry crane bucket fullness detection system provided by the disclosed embodiments include: This embodiment monitors hydraulic cylinder pressure through a pressure detection module and bucket depth through an encoder; these two parameters together reflect the bucket load status. The main control module analyzes and determines this real-time data, and dynamically adjusts the gantry crane's output power through the power regulation module, thereby achieving precise control of the bucket fullness and optimizing operation. This not only improves the gantry crane's operating efficiency, but also reduces energy consumption and operating costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present disclosure, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.
[0026] Figure 1 This is a structural diagram of a hopper full detection system for a gantry crane provided in one embodiment of the present disclosure;
[0027] Figure 2is a structural diagram of a gantry crane full bucket detection system provided by another embodiment of the present disclosure;
[0028] Figure 3 It is a structural diagram of a gantry crane full bucket detection system provided in another embodiment of the present disclosure. DETAILED DESCRIPTION
[0029] To help those skilled in the art better understand this solution, the following will clearly describe the technical solutions in the embodiments of this solution in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of this solution, not all of it. Based on the embodiments of this solution, all other embodiments obtained by those skilled in the art without creative work should fall within the scope of protection of this solution.
[0030] Throughout the specification, claims, and accompanying figures of this solution, the term "including" and any variations thereof mean "including, but not limited to," and are intended to cover non-exclusive inclusions and are not limited to the examples listed herein. Furthermore, the terms "first" and "second," etc., are used to distinguish between different objects, not to describe a specific order.
[0031] The following describes the implementation of the present disclosure in detail with reference to the accompanying drawings:
[0032] Figure 1 This is a structural diagram of the door crane full bucket detection system provided by the embodiment of the present disclosure. Figure 1 The gantry crane full bucket detection system includes: an encoder, a pressure detection module, a main control module and a power regulation module; the encoder, pressure detection module and power regulation module are all connected to the main control module; the encoder is configured to detect the digging depth of the bucket, the pressure detection module is configured to detect the pressure of the gantry crane hydraulic cylinder, and the power regulation module is configured to adjust the output power of the gantry crane.
[0033] In this embodiment, an encoder can be a sensor that converts rotational or linear displacement into an electrical signal (such as a pulse or digital signal). In a gantry crane full bucket detection system, the encoder can be installed on the bucket's lifting mechanism (such as a hydraulic cylinder or chain). This encoder converts the bucket's mechanical motion into an electrical signal, indirectly inferring the bucket's digging depth by measuring its rotational or extension length. As the bucket descends deeper into the material, the encoder's output signal changes accordingly, reflecting the bucket's depth.
[0034] The pressure detection module is configured to monitor the pressure in the hydraulic cylinder of the gantry crane. During the excavation process, the pressure in the hydraulic cylinder varies with the resistance applied to the bucket. By monitoring the hydraulic cylinder pressure, the bucket load can be indirectly determined. The pressure detection module uses a pressure sensor to convert the pressure within the hydraulic cylinder into an electrical signal. This electrical signal is transmitted to the main control module, which uses the pressure value to determine whether the bucket is full and the resistance applied during excavation.
[0035] The main control module receives signals from the encoder and pressure detection module, processes and analyzes them, and based on the analysis results, sends instructions to the power regulation module to adjust the gantry crane's output power. The main control module first reads the signals from the encoder and pressure detection module and then processes them. The power regulation module is configured to regulate the gantry crane's output power. Based on the control instructions from the main control module, the power regulation module adjusts the output power of the gantry crane's power system (such as the engine or electric motor). This can be achieved by changing the throttle position, adjusting the motor speed, or applying other control strategies. For example, when the encoder detects that the bucket's digging depth has reached a certain value and the pressure detection module detects that the hydraulic cylinder pressure has reached a certain threshold, the main control module can determine that the bucket is full. At this point, the main control module can send a command to the power regulation module to reduce the output power to prevent the gantry crane from overworking. Conversely, the main control module can increase the output power to improve digging efficiency.
[0036] As can be seen from the above, this embodiment monitors the hydraulic cylinder pressure through the pressure detection module and the bucket depth through the encoder. These two parameters together reflect the bucket load status. The main control module analyzes and determines based on this real-time data, and dynamically adjusts the gantry crane's output power through the power regulation module, thereby achieving precise control and optimized operation of the bucket full state. This not only improves the gantry crane's operating efficiency, but also reduces energy consumption and operating costs.
[0037] like Figure 2 As shown, in one embodiment of the present disclosure, it also includes: a camera module; the camera module is connected to the main control module; the camera module is configured to detect the loading amount of the gantry crane bucket.
[0038] In this embodiment, the camera module is configured to detect the load level of the gantry crane bucket. A camera installed in a suitable position captures the bucket in real time, capturing image information. The camera transmits the captured image information to the main control module. The main control module uses image recognition technology to analyze and process the image to determine the bucket's load level. For example, the load level can be estimated by identifying features such as the stacking height and covered area of the material within the bucket. Furthermore, multiple cameras, viewed from different angles, can be combined to obtain more comprehensive bucket image information, improving detection accuracy.
[0039] For example, at a port terminal, a gantry crane is performing cargo loading and unloading operations.
[0040] An encoder is installed on the gantry crane. As the crane's boom moves up and down, the encoder monitors the bucket's excavation depth in real time. As the bucket descends to excavate cargo, the encoder continuously transmits depth data to the main control module. Simultaneously, a pressure detection module uses a pressure sensor installed on the gantry crane's hydraulic cylinder to detect changes in hydraulic cylinder pressure during operation. During excavation, as the bucket contacts and exerts force on the cargo, the hydraulic cylinder's pressure gradually increases, and this pressure data is transmitted to the main control module. Furthermore, camera modules are installed at key locations on the gantry crane. These include a high-definition camera facing the bucket and another camera from the side. These cameras capture images of the bucket in real time and transmit this information to the main control module. The main control module uses advanced image recognition algorithms to analyze the height and area covered by the cargo within the bucket to determine the load. During operation, the main control module integrates the encoder's depth data, the pressure data from the pressure detection module, and the image analysis results from the camera module. When the encoder detects that the bucket has descended to a certain depth, the pressure detection module detects that the hydraulic cylinder pressure has reached a specific threshold, and the camera module's image analysis indicates that the bucket is nearly full, the main control module determines that the bucket is nearly full. At this point, the main control module sends a command to the power regulation module. This module, which can be a frequency converter, responds by reducing the motor speed of the portal crane, thereby reducing the crane's output power. This prevents overloading the bucket and reduces energy consumption and mechanical wear on the portal crane.
[0041] Through this gantry crane full bucket detection system, the port terminal can improve cargo loading and unloading efficiency, reduce equipment maintenance costs, and ensure safe and stable operations.
[0042] like Figure 2 As shown, in one embodiment of the present disclosure, it also includes: a fill light module; the fill light module is connected to the main control module; the fill light module is configured to perform fill light on the camera module.
[0043] In this embodiment, the fill light module is configured to provide appropriate lighting conditions for the camera module during image capture. Because the operating environment of a door operator is complex, and lighting conditions may vary depending on factors such as time of day and weather, the fill light module's function is to provide sufficient light for the camera module in insufficient light conditions, thereby ensuring image quality and clarity.
[0044] In this embodiment, the fill light module can be composed of a set of high-intensity LED lights or other lighting devices. These lights can be adjusted in brightness and angle as needed. When the main control module determines that the camera module needs to capture an image, it can simultaneously send a signal to the fill light module. After receiving the signal, the fill light module activates the lighting device to provide the necessary illumination for the camera module. For example, in low light conditions such as at night or on cloudy days, the fill light module automatically turns on to ensure that the camera module can capture a clear image of the bucket.
[0045] From the above, it can be concluded that after adding the fill light module in this embodiment, the adaptability of the gantry crane full bucket detection system in complex lighting environments is improved, ensuring that the camera module can capture high-quality, high-definition bucket images under any conditions, thereby improving the accuracy and reliability of load detection.
[0046] like Figure 2 As shown, in one embodiment of the present disclosure, it also includes: a light intensity detection module; the light intensity detection module is connected to the main control module; the light intensity detection module is configured to detect the light intensity of the door machine working environment.
[0047] In this embodiment, the light intensity detection module is configured to detect the light intensity of the door operator's operating environment. This allows the main control module to properly control the fill light module based on changes in light intensity, ensuring that the camera module captures images under optimal lighting conditions.
[0048] In this embodiment, the light intensity detection module can be a device such as a photosensor that can sense the ambient light intensity and convert it into an electrical signal for transmission to the main control module. The photosensor can generate different resistance or voltage values depending on the light intensity. The main control module determines the current light intensity level by reading these values.
[0049] As can be seen from the above, by adding a light intensity detection module, this embodiment enables the gantry crane's bucket fullness detection system to more intelligently adapt to varying lighting environments, ensuring that the camera module consistently captures high-quality image information. The close collaboration between these modules enables the gantry crane to accurately detect the bucket status and appropriately adjust output power under various operating conditions, improving its efficiency, safety, and reliability.
[0050] like Figure 3 As shown, in one embodiment of the present disclosure, it also includes: a photovoltaic power generation module; the photovoltaic power generation module is used to convert light energy into electrical energy, and the photovoltaic power generation module is configured to provide working power to the door crane full bucket detection system.
[0051] In this embodiment, the photovoltaic power generation module converts light energy into electrical energy, providing operating power for the various modules of the hopper-full detection system. This module reduces reliance on traditional grid power, lowering energy costs while also meeting energy conservation and environmental protection requirements.
[0052] In this embodiment, the photovoltaic power generation module primarily consists of a solar panel and a controller. The solar panel receives sunlight and converts it into direct current (DC). The controller regulates and manages the power output from the solar panel. When the hopper fullness detection system requires power, the solar panel provides stable DC power to each module via the controller.
[0053] As can be seen from the above, by adding a photovoltaic power generation module, the gantry crane's full-bucket detection system has achieved energy self-sufficiency, reducing dependence on traditional energy sources and improving the system's sustainability and environmental friendliness. Furthermore, the photovoltaic module's stable power supply ensures the proper functioning of all modules, enabling the gantry crane to perform cargo loading and unloading operations more efficiently and safely.
[0054] like Figure 3 As shown, in one embodiment of the present disclosure, it also includes: a power switching module and a battery; the control end of the power switching module is connected to the main control module, the first end of the power switching module is connected to the photovoltaic power generation module, and the second end of the power switching module is connected to the battery.
[0055] In this embodiment, the battery serves as an energy storage device for storing the electrical energy generated by the photovoltaic power generation module and providing backup power to the system when needed. The battery can maintain the system's short-term operation in situations such as insufficient photovoltaic power generation or a sudden power outage, ensuring data is not lost and a stable system transition. When the photovoltaic power generation module generates electrical energy, a portion of the energy can be stored in the battery through a charging circuit. The battery is typically a rechargeable chemical battery, such as a lead-acid battery or a lithium-ion battery. During discharge, the battery converts the stored chemical energy into electrical energy, which is then used to power the various modules of the system through the power switching module.
[0056] The main function of the power switching module is to automatically switch the system's power source according to different power supply conditions. The power switching module can switch between the photovoltaic power generation module and the battery to ensure that the system always has a stable power supply. The control end of the power switching module is connected to the main control module, which controls the switching of the power switching module based on the system's power requirements and the status of each power source. The first end of the power switching module is connected to the photovoltaic power generation module. When the power output of the photovoltaic power generation module meets the system's requirements, the power switching module will select the photovoltaic power generation module as the system's power source. If the power output of the photovoltaic power generation module is insufficient or unstable, the second end of the power switching module is connected to the battery. At this time, the switching module will automatically switch to the battery, and the battery will power the system.
[0057] As can be seen from the above, the addition of a power switching module and batteries in this embodiment makes the hopper-full detection system for the gantry crane more flexible and reliable in terms of power supply. This embodiment fully utilizes the clean energy of photovoltaic power generation, while relying on the batteries to provide backup power when necessary, ensuring continuous and stable operation of the system and improving the efficiency and safety of the gantry crane.
[0058] like Figure 3 As shown, in one embodiment of the present disclosure, it also includes: a charging control module and a discharging control module; the first end of the charging control module is connected to the photovoltaic power generation module, and the second end of the charging control module is connected to the battery; the first end of the discharging control module is connected to the battery, and the second end of the discharging control module is used to output the door crane full bucket detection system to provide working power.
[0059] In this embodiment, the charging control module is primarily used to control the photovoltaic power generation module's charging of the battery. The charging control module regulates the charging current and voltage to prevent overcharging and protect the battery's lifespan and safety. The first end of the charging control module is connected to the photovoltaic power generation module to receive its output electrical energy. When the photovoltaic power generation module generates electrical energy, the charging control module regulates the input electrical energy based on the battery's status and charging requirements. For example, by controlling the charging current, excessive current can be prevented from damaging the battery. The charging control module also monitors the battery's voltage and automatically stops charging when the battery is fully charged to prevent overcharging.
[0060] In this embodiment, the discharge control module is used to control the discharge process of the battery to the various modules of the door crane full bucket detection system. The discharge control module can stabilize the output voltage and current to ensure the normal operation of the system, while preventing over-discharge and protecting the battery. The first end of the discharge control module is connected to the battery. When the door crane full bucket detection system requires power, the discharge control module obtains electrical energy from the battery. The discharge control module adjusts the output voltage and current according to the load requirements of the system to meet the working requirements of each module. For example, when the system load is large, the discharge control module can increase the output current to ensure stable operation of the system. At the same time, the discharge control module also monitors the battery voltage. When the battery power is too low, the discharge is automatically cut off to prevent irreversible damage to the battery due to over-discharge.
[0061] As can be seen from the above, the addition of the charging and discharging control modules in this embodiment makes the power management of the door crane full bucket detection system more sophisticated and reliable. These two modules work in conjunction with other modules to ensure safe battery charging and discharging, providing a stable operating power supply for the system, improving the efficiency and safety of the door crane, and extending the battery life.
[0062] The above embodiments are only used to illustrate the technical solutions of the present disclosure, rather than to limit them. Although the present disclosure has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present disclosure.
Claims
1. A gantry crane full bucket detection system, characterized in that: include: Encoder, pressure detection module, main control module and power regulation module; The encoder, the pressure detection module and the power regulation module are all connected to the main control module; The encoder is configured to detect the excavation depth of the bucket, the pressure detection module is configured to detect the pressure of the hydraulic cylinder of the portal crane, and the power adjustment module is configured to adjust the output power of the portal crane.
2. The door crane full bucket detection system according to claim 1, characterized in that: Also includes: Camera module; The camera module is connected to the main control module; The camera module is configured to detect the loading amount of the gantry crane bucket.
3. The door crane full bucket detection system according to claim 2, characterized in that: Also includes: Fill light module; The fill light module is connected to the main control module; The fill light module is configured to provide fill light for the camera module.
4. The door crane full bucket detection system according to claim 3, characterized in that: Also includes: Light intensity detection module; The light intensity detection module is connected to the main control module; The light intensity detection module is configured to detect the light intensity of the door crane working environment.
5. The door crane full bucket detection system according to claim 1, characterized in that: Also includes: Photovoltaic power generation modules; The photovoltaic power generation module is used to convert light energy into electrical energy, and the photovoltaic power generation module is configured to provide working power to the door crane full bucket detection system.
6. The door crane full bucket detection system according to claim 5, characterized in that: Also includes: Power switching module and battery; The control end of the power switching module is connected to the main control module, the first end of the power switching module is connected to the photovoltaic power generation module, and the second end of the power switching module is connected to the battery.
7. The door crane full bucket detection system according to claim 6, characterized in that: Also includes: Charging control module and discharging control module; The first end of the charging control module is connected to the photovoltaic power generation module, and the second end of the charging control module is connected to the battery; The first end of the discharge control module is connected to the battery, and the second end of the discharge control module is used to output the door crane full bucket detection system to provide working power.