Distributed synchronous acquisition system for crane data

Abstract

The utility model discloses a crane data distributed synchronous acquisition system which comprises a master station node and a sampling terminal, and the sampling terminal comprises a switching value input terminal, an analog quantity input terminal and an incremental encoder input terminal; the master station node is in two-way communication with the crane safety monitoring system through the first communication module; the master station node is in two-way communication with a switching value input terminal, an analog quantity input terminal and an incremental encoder input terminal through a second communication module; the other end of the switching value input terminal is provided with a digital quantity acquisition module, the other end of the analog quantity input terminal is provided with an analog quantity acquisition module, and the other end of the incremental encoder input terminal is provided with a high-speed pulse acquisition module. The problem that the distributed synchronous acquisition efficiency of crane data is low due to the fact that interference signals are easily sensed in a cable when a long-distance cable is adopted for analog signal transmission traditionally is solved.

Description

Technical Field

[0001] This utility model relates to the field of data acquisition technology, and in particular to a distributed synchronous data acquisition system for cranes. Background Technology

[0002] Traditional crane safety monitoring systems often use PLCs as data acquisition terminals. PLCs employ backplane bus communication, and the sensors and devices being monitored need to transmit signals via cables to an electrical control panel for PLC data acquisition. This traditional solution achieves high synchronization of data acquisition from various sensors and simplifies centralized equipment debugging. However, it also has certain drawbacks: First, crane applications involve high-power equipment with complex high-power power supply interference. Using long-distance cables for analog signal transmission can easily introduce interference signals into the cables, causing measurement errors that affect control and protection results. Second, as cranes become increasingly intelligent, the amount of data requiring acquisition is also increasing. Upgrades and expansions require not only adding PLC acquisition modules but also upgrading the corresponding software. Utility Model Content

[0003] This invention provides a distributed synchronous data acquisition system for cranes to overcome the aforementioned technical problems.

[0004] To achieve the above objectives, the technical solution of this utility model is as follows:

[0005] A distributed synchronous data acquisition system for cranes includes a master station node and sampling terminals, wherein the sampling terminals include at least a digital input terminal, an analog input terminal, and an incremental encoder input terminal.

[0006] The master station node is bidirectionally connected to the pre-installed crane safety monitoring system through the first communication module; the master station node is bidirectionally connected to the digital input terminal, analog input terminal and incremental encoder input terminal through the second communication module.

[0007] The switch input terminal is equipped with a digital acquisition module, which is used to acquire the switch information of the crane and feed it back to the switch input terminal. The switch information includes at least limit switch signals, operation command signals and braking status signals.

[0008] The analog input terminal is equipped with an analog acquisition module, which is used to acquire the lifting weight sensor signal and feed it back to the analog input terminal;

[0009] The incremental encoder input terminal is equipped with a high-speed pulse acquisition module, which is used to acquire the lifting height signal of the crane through the incremental encoder and feed it back to the incremental encoder input terminal.

[0010] The master station node is used to communicate with the sampling terminal through the second communication module, and then send a data synchronization acquisition broadcast message to the sampling terminal within a set data acquisition period based on a preset private communication protocol. It also feeds back the signals of each terminal collected by the sampling terminal to the master station node and transmits them to the crane safety monitoring system through the first communication module to store the signals of each terminal corresponding to each data acquisition period.

[0011] Furthermore, the first communication module adopts an Ethernet communication module;

[0012] The second communication module includes an RS485 communication module as the main communication module and a LoRa communication module as a backup communication module.

[0013] Furthermore, the master station node adopts a first microcontroller MCU1, and the model of the first microcontroller MCU1 is CKS32F103VET6;

[0014] The digital input terminal uses a second microcontroller MCU2;

[0015] The analog input terminal uses a third microcontroller MCU3;

[0016] The incremental encoder input terminal uses a fourth microcontroller MCU4;

[0017] Furthermore, the second microcontroller MCU2, the third microcontroller MCU3, and the fourth microcontroller MCU4 are all CKS32F103RBT6.

[0018] Furthermore, the circuit corresponding to the digital acquisition module includes an optocoupler U1. Pin 1 of the optocoupler U1 is connected to one end of a first resistor R1 and one end of a first capacitor C1. The other end of the first resistor R1 is connected to the Digital_Input pin for connecting an external switch sensor. The other end of the first capacitor C1 is grounded. Pin 3 of the optocoupler U1 is connected to one end of a third resistor R3. The other end of the third resistor R3 is connected to the Input_COM pin for connecting an external switch sensor. Pin 6 of the optocoupler U1 is connected to one end of a second resistor R2, one end of a second capacitor C2, and the MCU_Input terminal. The MCU_Input terminal is connected to the PB12 pin of the second microcontroller MCU2. Pin 4 of the optocoupler U1 is grounded to the other end of the second capacitor C2. The other end of the second resistor R2 is connected to the VCC_3.3V terminal.

[0019] Furthermore, the circuit corresponding to the analog quantity acquisition module includes an analog quantity switch chip U2, an analog quantity isolation transmitter U3, and a voltage follower U4.

[0020] Pins 3, 6, 7, and 8 of the analog switch chip U2 are grounded; pin 13 of the analog switch chip U2 is connected to one end of the fifth resistor R5 and pin 9 of the analog isolation transmitter U3; the other end of the fifth resistor R5 is grounded to pin 8 of the analog isolation transmitter U3; pin 1 of the analog isolation transmitter U3 is connected to one end of the fourth resistor R4; pin 11 of the analog isolation transmitter U3 is grounded; pin 17 of the analog isolation transmitter U3 is grounded to one end of the third capacitor C3 and one end of the fourth capacitor C4; pin 18 of the analog isolation transmitter U3 is grounded to... The other end is connected to one end of the first inductor L1, and the other end of the first inductor L1 is connected to the other end of the fourth capacitor C4, which is connected to the +24V terminal; the other end of the fourth resistor R4 is connected to one end of the sixth resistor R6 and pin 1 of the voltage follower U4, and the other end of the sixth resistor R6 is grounded; pin 2 of the voltage follower U4 is grounded, and pin 5 of the voltage follower U4 is connected to the VCC_3.3V terminal; pins 3 and 4 of the voltage follower U4 are connected to the MCU_AD terminal, and the MCU_AD terminal is connected to the PC2 pin of the third microcontroller MCU3.

[0021] Furthermore, the circuit corresponding to the high-speed pulse acquisition module includes a first high-speed optocoupler U5 and a second high-speed optocoupler U6.

[0022] Pin 2 of the first high-speed optocoupler U5 is connected to one end of the seventh resistor R7. The other end of the seventh resistor R7 is connected to one end of the fifth capacitor C5 and the positive output terminal A+ of the differential pulse signal output line A in the incremental encoder. Pin 3 of the first high-speed optocoupler U5 is connected to the other end of the fifth capacitor C5 and the inverted output terminal A- of the differential pulse signal output line A in the incremental encoder. Pin 7 of the first high-speed optocoupler U5 is connected to one end of the eighth resistor R8. Pin 8 of the first high-speed optocoupler U5 and the other end of the eighth resistor R8 are connected to the +5V terminal. Pin 6 of the first high-speed optocoupler U5 is connected to one end of the ninth resistor R9 and the Input_A terminal. The Input_A terminal is connected to the PA0 pin of the fourth microcontroller MCU4. The other end of the ninth resistor R9 is connected to the VCC_3.3V terminal. Pin 5 of the first high-speed optocoupler U5 is grounded.

[0023] Pin 2 of the second high-speed optocoupler U6 is connected to one end of the tenth resistor R10. The other end of the tenth resistor R10 is connected to one end of the sixth capacitor C6 and the positive output terminal B+ of the differential pulse signal output B line in the incremental encoder. Pin 3 of the second high-speed optocoupler U6 is connected to the other end of the sixth capacitor C6 and the inverted output terminal B- of the differential pulse signal output B line in the incremental encoder. Pin 7 of the second high-speed optocoupler U6 is connected to one end of the eleventh resistor R11. Pin 8 of the second high-speed optocoupler U6 is connected to the eleventh resistor R11. The other end of resistor R11 is connected to the +5V terminal; pin 6 of the second high-speed optocoupler U6 is connected to one end of the twelfth resistor R12 and the Input_B terminal, which is connected to the PA1 pin of the fourth microcontroller MCU4; the other end of the twelfth resistor R12 is connected to the VCC_3.3V terminal; pin 5 of the second high-speed optocoupler U6 is grounded; the pulse signal differential output line A and the pulse signal differential output line B are two pulse signal differential output lines with a 90° phase difference in the incremental encoder.

[0024] Furthermore, the analog switch chip U2 is model CD4052; the analog isolation transmitter U3 is model TE5634; the voltage follower U4 is model LMV321; and the first high-speed optocoupler U5 and the second high-speed optocoupler U6 are model 6N137.

[0025] Beneficial Effects: This utility model provides a distributed synchronous data acquisition system for cranes. By splitting the acquisition system into a master station node and sampling terminals, and installing the sampling terminals near the sensors or equipment being measured, external interference introduced by cables is reduced, improving the accuracy of data acquisition. Simultaneously, to compensate for the data acquisition asynchrony problem caused by communication bandwidth limitations in distributed deployment, this utility model uses a crane safety monitoring system to send acquisition commands to the master station node via a first communication module. After the master station node connects with the sampling terminals via a second communication module, it sends data synchronization acquisition broadcast messages to the sampling terminals within a set data acquisition cycle based on a preset private communication protocol. The signals collected by each terminal are fed back to the master station node and transmitted to the crane safety monitoring system via the first communication module for storage of the terminal signals corresponding to each data acquisition cycle. The first and second communication modules control the synchronous data acquisition of the sampling terminals, improving the efficiency of distributed synchronous data acquisition for cranes. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the distributed synchronous data acquisition system for cranes according to this utility model;

[0028] Figure 2 This is a schematic diagram of the digital acquisition module in this embodiment;

[0029] Figure 3 This is a schematic diagram of the analog signal acquisition module in this embodiment;

[0030] Figure 4 This is a schematic diagram of the high-speed pulse acquisition module in this embodiment;

[0031] Figure 5 This is a schematic diagram of the RS485 communication module in this embodiment;

[0032] Figure 6 For this embodiment Communication module schematic diagram;

[0033] Figure 7 This is a schematic diagram of the Ethernet communication module in this embodiment.

[0034] Figure 8 This is the core block diagram of the crane data distributed synchronous acquisition system in this embodiment. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0036] This embodiment provides a distributed synchronous data acquisition system for cranes, such as... Figure 1 and Figure 8As shown, it includes a master station node, a first communication module, a second communication module, and a sampling terminal. The sampling terminal includes at least a digital input terminal, an analog input terminal, and an incremental encoder input terminal. The first communication module is an Ethernet communication module. The second communication module includes an RS485 communication module as the main communication module and a LoRa communication module as a backup communication module.

[0037] The master station node is bidirectionally connected to the pre-installed crane safety monitoring system through the first communication module; the master station node is bidirectionally connected to the digital input terminal, analog input terminal and incremental encoder input terminal through the second communication module.

[0038] The switch input terminal is equipped with a digital acquisition module, which is used to acquire the switch information of the crane and feed it back to the switch input terminal. The switch information includes at least limit switch signals, operation command signals and braking status signals.

[0039] The analog input terminal is equipped with an analog acquisition module, which is used to acquire the lifting weight sensor signal and feed it back to the analog input terminal;

[0040] The incremental encoder input terminal is equipped with a high-speed pulse acquisition module, which is used to acquire the lifting height signal of the crane through the incremental encoder and feed it back to the incremental encoder input terminal.

[0041] The crane safety monitoring system is used to communicate with the master station node based on the self-negotiation networking mechanism configured by the first communication module. The master station node is used to communicate with the sampling terminal through the second communication module. Based on a preset private communication protocol, it sends data synchronization acquisition broadcast messages to the sampling terminal within a set data acquisition cycle. It also feeds back the signals of each terminal collected by the sampling terminal to the master station node and transmits them to the crane safety monitoring system through the first communication module to store the terminal signals corresponding to each data acquisition cycle. The Ethernet self-negotiation networking principle is to automatically determine and configure the most suitable network parameters through communication between devices to achieve the maximum transmission rate and optimal performance. The self-negotiation function allows a network device to convey its supported working mode information to the peer on the network and accept the corresponding information that the peer may transmit, thereby solving the self-negotiation problem of duplex and 10M / 100M speed. The self-negotiation function is implemented entirely by the physical layer chip, so it does not use dedicated data packets or incur any high-level protocol overhead. The basic mechanism of the self-negotiation function is that each network device sends an FLP (Fast Connection Pulse) when powered on, when a management command is issued, or when a user intervenes. The negotiation information is encapsulated in these FLP sequences. The FLT contains clock / digital sequences, and extracting this data allows you to determine the operating modes supported by the peer device.

[0042] In this embodiment, the self-negotiation network-based distributed crane data synchronization acquisition device includes a master station node, digital input terminals, analog input terminals, and incremental encoder input terminals. The type and number of terminals can be selected according to the data acquisition needs at the crane site. The digital input terminals are equipped with digital sampling circuits with high-voltage resistance. Their main function is to accurately acquire digital information such as limit switches, operating commands, and braking status at the crane site. At the crane site, digital sensors generally use dry contact or open-collector output forms. The signals output by the digital output sensors are converted into corresponding high and low level signals by the digital acquisition module of the digital input terminal. Subsequently, the microcontroller MCU2 in the digital input terminal acquires these high and low levels and then uploads the sampled information to the master station node through an RS485 communication module or a LoRa communication module.

[0043] The analog input terminal samples 4-20mA analog signals, calculates the crane load tonnage information from the crane weight sensor signals, and the current signals output from multiple crane weight sensors are switched by the analog switch of the analog acquisition module before entering the analog isolation transmitter of the analog acquisition module. The microcontroller MCU3 performs analog-to-digital conversion on the analog signal output from the isolation transmitter to obtain digital information of the analog quantity. The microcontroller MCU3 also converts the digital information of the analog quantity into the actual load tonnage information of the crane.

[0044] The incremental encoder input terminal is based on a high-speed pulse sampling circuit. It calculates the number of encoder revolutions through pulse capture and records the current number of revolutions to a non-volatile memory during power-off. The quadrature pulse signal output by the incremental encoder is protected by a high-speed optocoupler in the high-speed pulse acquisition module before entering the microcontroller MCU4. The MCU's built-in quadrature pulse counting function acquires the encoder's rotation information and converts it into the number of revolutions, expressed as:

[0045] h = (h2–h1) / (rev2–rev1)×rev–h_corr

[0046] In the formula: h represents the real-time lifting height of the crane; rev represents the real-time number of revolutions of the incremental encoder; h2 represents the lifting height of the crane when the encoder number of revolutions is rev2; h1 represents the lifting height of the crane when the encoder number of revolutions is rev1; h_corr represents the cumulative error of the height.

[0047] All three terminals utilize the same wired and wireless communication methods. Wired communication employs electrically isolated RS485 communication, while wireless communication uses LoRa communication. The master node is responsible for collecting, processing, and forwarding data from the sampling terminals. The method used by the master node for data collection, processing, and forwarding is based on existing technology and will not be elaborated further. One end of the master node uses an RS485 and LoRa communication module, while the other end uses a 10M / 100M Ethernet communication module. For crane operation scenarios, to ensure communication reliability and real-time performance, while also considering ease of construction and expansion, the master node communicates with the three sampling terminals (digital input terminal, analog input terminal, and incremental encoder input terminal) via an RS485 bus or wireless LoRa. When using RS485 communication, wireless LoRa serves as a backup; if the RS485 communication bus is not connected or malfunctions, wireless LoRa communication automatically connects and transmits data.

[0048] In this embodiment, the master station node adopts a first microcontroller MCU1, and the model of the first microcontroller MCU1 is CKS32F103VET6;

[0049] The digital input terminal uses a second microcontroller MCU2;

[0050] The analog input terminal uses a third microcontroller MCU3;

[0051] The incremental encoder input terminal uses a fourth microcontroller MCU4;

[0052] Furthermore, the second microcontroller MCU2, the third microcontroller MCU3, and the fourth microcontroller MCU4 are all CKS32F103RBT6.

[0053] like Figure 2 As shown, the circuit corresponding to the digital signal acquisition module in this embodiment includes an optocoupler U1. Pin 1 of the optocoupler U1 is connected to one end of a first resistor R1 and one end of a first capacitor C1. The other end of the first resistor R1 is connected to the Digital_Input pin for connecting an external switch sensor. The other end of the first capacitor C1 is grounded. Pin 3 of the optocoupler U1 is connected to one end of a third resistor R3. The other end of the third resistor R3 is connected to the Input_COM pin for connecting an external switch sensor. Pin 6 of the optocoupler U1 is connected to one end of a second resistor R2, one end of a second capacitor C2, and the MCU_Input terminal. The MCU_Input terminal is connected to the PB12 pin of the second microcontroller MCU2. Pin 4 of the optocoupler U1 is grounded, and the other end of the second resistor R2 is connected to the VCC_3.3V terminal. In this embodiment, the switch input terminal includes 16 channels of digital signal acquisition, and the principle of each signal is the same. U1 is an optocoupler, model TLP185GB. The external digital 24V voltage signal is converted into a TTL level that the MCU can acquire after passing through the U1 optocoupler. Digital_Input and Input_COM are connected to the external preset switch sensor, and MCU_Input is connected to the PB12 pin of the microcontroller MCU2 (model CKS32F103RBT6).

[0054] like Figure 3 As shown, the circuit corresponding to the analog quantity acquisition module in this embodiment includes an analog quantity switch chip U2, an analog quantity isolation transmitter U3, and a voltage follower U4; wherein the analog quantity switch chip U2 is model CD4052; the analog quantity isolation transmitter U3 is model TE5634; and the voltage follower U4 is model LMV321.

[0055] Pins 3, 6, 7, and 8 of the analog switch chip U2 are grounded; pin 13 of the analog switch chip U2 is connected to one end of the fifth resistor R5 and pin 9 of the analog isolation transmitter U3; the other end of the fifth resistor R5 is grounded to pin 8 of the analog isolation transmitter U3; pin 1 of the analog isolation transmitter U3 is connected to one end of the fourth resistor R4; pin 11 of the analog isolation transmitter U3 is grounded; pin 17 of the analog isolation transmitter U3 is grounded to one end of the third capacitor C3 and one end of the fourth capacitor C4; pin 18 of the analog isolation transmitter U3 is grounded to... The other end is connected to one end of the first inductor L1, and the other end of the first inductor L1 is connected to the other end of the fourth capacitor C4, which is connected to the +24V terminal. The other end of the fourth resistor R4 is connected to one end of the sixth resistor R6 and pin 1 of the voltage follower U4, and the other end of the sixth resistor R6 is grounded. Pin 2 of the voltage follower U4 is grounded, and pin 5 of the voltage follower U4 is connected to the VCC_3.3V terminal. Pins 3 and 4 of the voltage follower U4 are connected to the MCU_AD terminal, and the MCU_AD terminal is connected to the PC2 pin of the third microcontroller MCU3. In this embodiment, the analog input terminal includes 4 channels of analog signal acquisition. U2 (model CD4052) is a 4-to-1 analog switch, U3 (model TE5634) is an analog isolation transmitter, and U4 (model LMV321) is a voltage follower. External analog signals are connected to Signal0, Signal1, Signal2, and Signal3. First, they are selected by the U2 analog switch and enter the analog isolation transmitter. The voltage signal output by the analog isolation transmitter is divided by R4 and R6 and then enters the impedance matching circuit implemented by the U4 voltage follower. Finally, the MCU_AD signal enters the PC2 pin of the microcontroller MCU3 (model CKS32F103RBT6) for AD analog-to-digital conversion.

[0056] like Figure 4 As shown, the circuit corresponding to the high-speed pulse acquisition module in this embodiment includes a first high-speed optocoupler U5 and a second high-speed optocoupler U6; wherein the first high-speed optocoupler U5 and the second high-speed optocoupler U6 are of model 6N137.

[0057] Pin 2 of the first high-speed optocoupler U5 is connected to one end of the seventh resistor R7. The other end of the seventh resistor R7 is connected to one end of the fifth capacitor C5 and the positive output terminal A+ of the differential pulse signal output line A in the incremental encoder. Pin 3 of the first high-speed optocoupler U5 is connected to the other end of the fifth capacitor C5 and the inverted output terminal A- of the differential pulse signal output line A in the incremental encoder. Pin 7 of the first high-speed optocoupler U5 is connected to one end of the eighth resistor R8. Pin 8 of the first high-speed optocoupler U5 and the other end of the eighth resistor R8 are connected to the +5V terminal. Pin 6 of the first high-speed optocoupler U5 is connected to one end of the ninth resistor R9 and the Input_A terminal. The Input_A terminal is connected to the PA0 pin of the fourth microcontroller MCU4. The other end of the ninth resistor R9 is connected to the VCC_3.3V terminal. Pin 5 of the first high-speed optocoupler U5 is grounded.

[0058] Pin 2 of the second high-speed optocoupler U6 is connected to one end of the tenth resistor R10. The other end of the tenth resistor R10 is connected to one end of the sixth capacitor C6 and the positive output terminal B+ of the differential pulse signal output B line in the incremental encoder. Pin 3 of the second high-speed optocoupler U6 is connected to the other end of the sixth capacitor C6 and the inverted output terminal B- of the differential pulse signal output B line in the incremental encoder. Pin 7 of the second high-speed optocoupler U6 is connected to one end of the eleventh resistor R11. Pin 8 of the second high-speed optocoupler U6 is connected to the eleventh resistor R11. The other end of resistor R11 is connected to the +5V terminal; pin 6 of the second high-speed optocoupler U6 is connected to one end of the twelfth resistor R12 and the Input_B terminal, which is connected to the PA1 pin of the fourth microcontroller MCU4; the other end of the twelfth resistor R12 is connected to the VCC_3.3V terminal; pin 5 of the second high-speed optocoupler U6 is grounded; the pulse signal differential output line A and the pulse signal differential output line B are two pulse signal differential output lines with a 90° phase difference in the incremental encoder. In this embodiment, the encoder input terminal includes three incremental encoder samples, and the sampling principle of each signal is the same. U5 and U6 (6N137) are high-speed optocouplers with the same parameters. The incremental encoder includes two pulse signal differential output lines A and B with a 90° phase difference. The position is obtained by counting pulses and the direction is determined by the phase relationship. The positive output terminal of the A phase signal is A+, and the negative output terminal of the A phase signal is A-. The positive output terminal of the B phase signal is B+, and the negative output terminal of the B phase signal is B-. In this embodiment, when the incremental encoder rotates, the A+ and A-, B+ and B- lines alternately output 24V and -24V voltages. This voltage signal is converted to TTL level after passing through the high-speed optocoupler. The microcontroller MCU4 (model CKS32F103RBT6) obtains the number of pulses output by the encoder through the built-in quadrature pulse sampling, thereby calculating the number of revolutions the encoder has made, and thus obtaining the real-time lifting height of the crane. The Input_A and Input_B pins are connected to the PA0 and PA1 pins of MCU4.

[0059] like Figure 5 The diagram shows the schematic of the RS485 communication module: U7 (model CA-IS3741) is an isolation bus chip, and U8 (model BL3085) is a 485 communication chip. Using U7 for isolation protection can shield against interference introduced by the 485 communication line between the master node and the terminal, improving product stability. RS485_A and RS485_B are connected to the serial communication network via the X1 terminal.

[0060] like Figure 6 The diagram shown is a schematic of the LoRa communication module: U10 is the LoRa communication module, which communicates with the MCU via... To facilitate communication, when wired communication is not used or is interrupted, the MCU will control the use of wireless communication to achieve data interaction between the master station node and the sampling terminal.

[0061] like Figure 7 The diagram shows the schematic of the Ethernet communication module: U9 (model CH395Q) is the Ethernet communication chip, integrating MAC and PHY functions, and RJ1 is the Ethernet RJ45 interface with an integrated network transformer. The microcontroller MCU1 (model CKS32F103VET6) of the master node communicates with the Ethernet communication chip U9 via the SPI bus (PA4, PA5, PA6, PA7).

[0062] The self-negotiation networking crane distributed data synchronization acquisition system described in this embodiment addresses the interference problem caused by long-distance transmission of crane field sensor signal lines. It utilizes a combination of a master station node and input terminals, collecting sampled data based on serial communication. To ensure synchronization of data acquisition across terminals, the master station node employs a preset broadcast synchronization method to control the terminals' data acquisition. After system power-on, the master station node sends a preset broadcast message at a designated time according to the set data acquisition cycle to synchronize each sampling terminal. The broadcast message carries information about successfully registered sampling terminals and their frame intervals. Based on the messages sent by the input terminals, the master station node parses the sampling terminal's address and type in the registration frame, pre-creates a frame parsing method corresponding to the sampling terminal type, dynamically creates a corresponding sampling data buffer, reads the sampling data information from the data upload frame, and parses the corresponding data message into sampled data stored in the data buffer for forwarding based on the registered type of the sampling terminal. The sampling terminals are responsible for acquiring and uploading crane sensor data. After a sampling terminal connects to and starts the data acquisition system, it first sends a registration frame to proactively transmit its address and terminal type to the master node. Upon receiving a broadcast frame from the master node, it parses whether its registration has been successful. If successful, it transmits the sampling information to the master node via a data upload frame; otherwise, it continues to send registration frames to register the terminal. To ensure that the data transmission times of each sampling terminal do not conflict, a preset time-division multiple access (TDMA) method is used for terminal frame transmission. Each terminal determines its own transmission time slot based on its address and frame interval information and then sends its registration frame and data upload frame.

[0063] The self-negotiation networking distributed crane data acquisition system described in this embodiment has the following advantages: By splitting the acquisition system into a master node and sampling terminals, and installing the sampling terminals near the sensors or equipment being measured, external interference introduced by cables is reduced, improving the accuracy of data acquisition. To compensate for the data acquisition asynchrony problem caused by the limited communication bandwidth of distributed deployment, a private communication protocol is used to control the synchronous data acquisition of the sampling terminals. Simultaneously, the debugging cycle is shortened, ensuring flexible expansion of the data sampling device. Based on a pre-set private communication protocol, the first and second communication modules control the synchronous data acquisition of the sampling terminals, improving the efficiency of distributed synchronous crane data acquisition.

[0064] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A distributed synchronous data acquisition system for cranes, characterized in that, It includes a master station node and a sampling terminal, wherein the sampling terminal includes at least a digital input terminal, an analog input terminal and an incremental encoder input terminal; The master station node is bidirectionally connected to the pre-installed crane safety monitoring system through the first communication module; the master station node is bidirectionally connected to the digital input terminal, analog input terminal and incremental encoder input terminal through the second communication module. The switch input terminal is equipped with a digital acquisition module, which is used to acquire the switch information of the crane and feed it back to the switch input terminal. The switch information includes at least limit switch signals, operation command signals and braking status signals. The analog input terminal is equipped with an analog acquisition module, which is used to acquire the lifting weight sensor signal and feed it back to the analog input terminal; The incremental encoder input terminal is equipped with a high-speed pulse acquisition module, which is used to acquire the lifting height signal of the crane through the incremental encoder and feed it back to the incremental encoder input terminal. The master station node is used to communicate with the sampling terminal through the second communication module, and then send a data synchronization acquisition broadcast message to the sampling terminal within a set data acquisition period based on a preset private communication protocol. It also feeds back the signals of each terminal collected by the sampling terminal to the master station node and transmits them to the crane safety monitoring system through the first communication module to store the signals of each terminal corresponding to each data acquisition period.

2. The crane data distributed synchronous acquisition system according to claim 1, characterized in that, The first communication module uses an Ethernet communication module; The second communication module includes an RS485 communication module as the main communication module and a LoRa communication module as a backup communication module.

3. A distributed synchronous data acquisition system for cranes according to claim 2, characterized in that, The master station node adopts a first microcontroller MCU1, and the model of the first microcontroller MCU1 is CKS32F103VET6; The digital input terminal uses a second microcontroller MCU2; The analog input terminal uses a third microcontroller MCU3; The incremental encoder input terminal uses a fourth microcontroller MCU4; Furthermore, the second microcontroller MCU2, the third microcontroller MCU3, and the fourth microcontroller MCU4 are all CKS32F103RBT6.

4. A distributed synchronous data acquisition system for cranes according to claim 3, characterized in that, The circuit corresponding to the digital acquisition module includes an optocoupler U1. Pin 1 of the optocoupler U1 is connected to one end of a first resistor R1 and one end of a first capacitor C1. The other end of the first resistor R1 is connected to the Digital_Input pin for connecting an external switch sensor. The other end of the first capacitor C1 is grounded. Pin 3 of the optocoupler U1 is connected to one end of a third resistor R3. The other end of the third resistor R3 is connected to the Input_COM pin for connecting an external switch sensor. Pin 6 of the optocoupler U1 is connected to one end of a second resistor R2, one end of a second capacitor C2, and the MCU_Input terminal. The MCU_Input terminal is connected to the PB12 pin of the second microcontroller MCU2. Pin 4 of the optocoupler U1 is grounded, and the other end of the second capacitor C2 is connected to the VCC_3.3V terminal.

5. A distributed synchronous data acquisition system for cranes according to claim 4, characterized in that, The circuit corresponding to the analog quantity acquisition module includes an analog quantity switch chip U2, an analog quantity isolation transmitter U3, and a voltage follower U4. Pins 3, 6, 7, and 8 of the analog switch chip U2 are grounded; pin 13 of the analog switch chip U2 is connected to one end of the fifth resistor R5 and pin 9 of the analog isolation transmitter U3; the other end of the fifth resistor R5 is grounded to pin 8 of the analog isolation transmitter U3; pin 1 of the analog isolation transmitter U3 is connected to one end of the fourth resistor R4; pin 11 of the analog isolation transmitter U3 is grounded; pin 17 of the analog isolation transmitter U3 is grounded to one end of the third capacitor C3 and one end of the fourth capacitor C4; pin 18 of the analog isolation transmitter U3 is grounded to... The other end is connected to one end of the first inductor L1, and the other end of the first inductor L1 is connected to the other end of the fourth capacitor C4, which is connected to the +24V terminal; the other end of the fourth resistor R4 is connected to one end of the sixth resistor R6 and pin 1 of the voltage follower U4, and the other end of the sixth resistor R6 is grounded; pin 2 of the voltage follower U4 is grounded, and pin 5 of the voltage follower U4 is connected to the VCC_3.3V terminal; pins 3 and 4 of the voltage follower U4 are connected to the MCU_AD terminal, and the MCU_AD terminal is connected to the PC2 pin of the third microcontroller MCU3.

6. A distributed synchronous data acquisition system for cranes according to claim 5, characterized in that, The circuit corresponding to the high-speed pulse acquisition module includes a first high-speed optocoupler U5 and a second high-speed optocoupler U6. Pin 2 of the first high-speed optocoupler U5 is connected to one end of the seventh resistor R7. The other end of the seventh resistor R7 is connected to one end of the fifth capacitor C5 and the positive output terminal A+ of the differential pulse signal output line A in the incremental encoder. Pin 3 of the first high-speed optocoupler U5 is connected to the other end of the fifth capacitor C5 and the inverted output terminal A- of the differential pulse signal output line A in the incremental encoder. Pin 7 of the first high-speed optocoupler U5 is connected to one end of the eighth resistor R8. Pin 8 of the first high-speed optocoupler U5 and the other end of the eighth resistor R8 are connected to the +5V terminal. Pin 6 of the first high-speed optocoupler U5 is connected to one end of the ninth resistor R9 and the Input_A terminal. The Input_A terminal is connected to the PA0 pin of the fourth microcontroller MCU4. The other end of the ninth resistor R9 is connected to the VCC_3.3V terminal. Pin 5 of the first high-speed optocoupler U5 is grounded. Pin 2 of the second high-speed optocoupler U6 is connected to one end of the tenth resistor R10. The other end of the tenth resistor R10 is connected to one end of the sixth capacitor C6 and the positive output terminal B+ of the differential pulse signal output B line in the incremental encoder. Pin 3 of the second high-speed optocoupler U6 is connected to the other end of the sixth capacitor C6 and the inverted output terminal B- of the differential pulse signal output B line in the incremental encoder. Pin 7 of the second high-speed optocoupler U6 is connected to one end of the eleventh resistor R11. Pin 8 of the second high-speed optocoupler U6 is connected to the eleventh resistor R11. The other end of resistor R11 is connected to the +5V terminal; pin 6 of the second high-speed optocoupler U6 is connected to one end of the twelfth resistor R12 and the Input_B terminal, which is connected to the PA1 pin of the fourth microcontroller MCU4; the other end of the twelfth resistor R12 is connected to the VCC_3.3V terminal; pin 5 of the second high-speed optocoupler U6 is grounded; the pulse signal differential output line A and the pulse signal differential output line B are two pulse signal differential output lines with a 90° phase difference in the incremental encoder.

7. A distributed synchronous data acquisition system for cranes according to claim 6, characterized in that, The analog switch chip U2 is model CD4052; the analog isolation transmitter U3 is model TE5634; the voltage follower U4 is model LMV321; and the first high-speed optocoupler U5 and the second high-speed optocoupler U6 are model 6N137.

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