High-efficiency energy-saving integrated crane control system
By integrating a smart anti-sway system and fully digital multi-control technology, a safety module, a height acquisition module, and a soft measurement module, and using a frequency converter to precisely control the crane motor, the swaying problem in traditional crane control systems is solved, achieving efficient, safe, and energy-saving crane operation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- HENAN NORMAL UNIV
- Filing Date
- 2025-06-18
- Publication Date
- 2026-07-21
Smart Images
Figure CN224530467U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of crane control technology, and more specifically to a high-efficiency and energy-saving integrated crane control system. Background Technology
[0002] The high-efficiency and energy-saving integrated crane control system integrates automated control and digital technology, combined with optimized operating curve design and a high-reliability design scheme, to ensure that the crane operates efficiently, safely, and energy-savingly. The intelligent multi-purpose crane transmission control system's main business is the sale of CS300 crane-specific frequency converter technology and its supporting software, with a specialty in the sale of supporting hardware and facilities, and core services including technology updates and maintenance.
[0003] Large cranes are currently widely used in numerous industries. However, these cranes typically operate in complex or harsh environments. In recent years, with the increasing frequency of trade between countries, cargo transportation has become a crucial part of economic activity. Cranes play a vital role in the loading and handling of goods. Bridge cranes and gantry cranes are widely used in large transportation facilities such as airports, docks, and factories. However, since the connection between the crane's displacement device and the cargo is often mediated by wire ropes, factors such as operator skill, the flexibility of the wire ropes, and wind force can often cause cargo to sway during transport. To ensure the safety and reliability of crane operation, high demands are placed on the crane's control system. However, traditional control methods suffer from relatively low starting torque and a narrow speed range. To better meet these requirements, the project team adopted variable frequency speed control technology. By detecting the sway angle using soft measurement technology and employing an estimated sway angle, a specific mathematical model was used to adjust the inverter's output and frequency, thereby controlling the actual operating speed of the mechanism and suppressing hook sway. Electronic anti-sway systems, as a new type of anti-sway measure, achieve automatic control, freeing sway reduction from human operation, and with further development, can also achieve unmanned operation. Utility Model Content
[0004] The purpose of this invention is to provide a high-efficiency and energy-saving integrated crane control system. By integrating safety, height acquisition, and soft measurement modules, the system monitors the operating status and outputs precise control signals to the frequency converter, thereby driving the motor to achieve efficient, safe, and energy-saving anti-sway control.
[0005] To achieve the above objectives, this utility model provides the following technical solution: A high-efficiency and energy-saving integrated crane control system includes: an intelligent anti-sway system and a frequency converter; The intelligent anti-sway system includes: a safety module, a height acquisition module, a soft measurement module, and a main control module; The main control module includes: a microprocessor, a sampling and conditioning circuit, a grating encoder signal isolation and conversion circuit, a resolver filter and decoding circuit, and a DA output circuit; The safety module and the altitude acquisition module are respectively connected to the soft measurement module; the soft measurement module is connected to the microprocessor via a digital interface; The sampling and conditioning circuit is connected to the microprocessor via an AD interface; the grating encoder signal isolation and conversion circuit is connected to the microprocessor via a GPIO interface; the resolver filter and decoding circuit is connected to the microprocessor via a first SPI interface; the microprocessor is connected to the DA output circuit via a second SPI interface; the DA output circuit is connected to the frequency converter, and the output port of the frequency converter is connected to the input terminals of the first motor, the second motor, and the third motor in the main circuit of the crane, respectively.
[0006] Furthermore, the main control module adopts a DSP+FPAG+CPLD architecture; The DSP and FPAG are connected via a serial data exchange interface; the CPLD is connected to the DSP via a first serial communication interface; and the CPLD is connected to the FPAG via a second serial communication interface.
[0007] Furthermore, the digital interfaces include, but are not limited to, SPI interfaces and GPIO interfaces.
[0008] Furthermore, the main circuit of the crane includes: a three-phase power supply, a first circuit breaker, a second circuit breaker, a third circuit breaker, a fourth circuit breaker, a first AC contactor, a second AC contactor, a third AC contactor, a fourth AC contactor, a fifth AC contactor, a sixth AC contactor, a first thermal relay, a second thermal relay, a third thermal relay, a soft starter, a first motor, a second motor, and a third motor; The input terminals of the first, second, third, and fourth circuit breakers are respectively connected to L1, L2, and L3 of the three-phase power supply; the output terminal of the first circuit breaker is connected to the power input terminal of the soft starter; the output terminal of the second circuit breaker is connected to the input terminal of the second AC contactor; the output terminal of the third circuit breaker is connected to the input terminal of the fourth AC contactor; the output terminal of the fourth circuit breaker is connected to the input terminal of the sixth AC contactor; the power output terminal of the soft starter is respectively connected to the input terminals of the first, third, and fifth AC contactors; the output terminal of the second AC contactor is connected to the input terminal of the first thermal relay; the output terminal of the fourth AC contactor is connected to the input terminal of the second thermal relay; the output terminal of the sixth AC contactor is connected to the input terminal of the third thermal relay; the output terminals of the first AC contactor and the first thermal relay are jointly connected to the terminals of the first motor; the output terminals of the third AC contactor and the second thermal relay are jointly connected to the terminals of the second motor; the output terminals of the fifth AC contactor and the third thermal relay are jointly connected to the terminals of the third motor.
[0009] Furthermore, the main control module includes a PWM hardware logic protection output circuit and a seven-segment digital tube status display; The PWM hardware logic protection output circuit is connected to the microprocessor through 12 groups of 24-channel PWM interfaces. The seven-segment display is connected to the microprocessor via the fourth I / O interface to display the motor status.
[0010] Furthermore, the main control module also includes: an external switch control input circuit, a motor status indication circuit, and a PWM drive fault return circuit; The external switch control input circuit is connected to the microprocessor through the first I / O interface; The 24-channel PWM drive fault return circuit is connected to the microprocessor through the second I / O interface; The motor status indication circuit is connected to the microprocessor via a third I / O interface.
[0011] Furthermore, the external switch control input circuit specifically comprises: the coils of the first AC contactor, the third AC contactor, and the fifth AC contactor connected in parallel; one end of each of the coils of the first AC contactor, the third AC contactor, and the fifth AC contactor is connected to the RUN port of the soft starter; the other end of each of the coils of the first AC contactor, the third AC contactor, and the fifth AC contactor is connected to the COM port of the soft starter; and the STOP port of the soft starter is connected to the COM port via a normally closed stop button.
[0012] Furthermore, the main circuit of the first motor is provided with a first current transformer, and the first current transformer is connected in series with a first ammeter; the main circuit of the second motor is provided with a second current transformer, and the second current transformer is connected in series with a second ammeter; the main circuit of the third motor is provided with a third current transformer, and the third current transformer is connected in series with a third ammeter.
[0013] Furthermore, the three-phase power supply is provided with a voltage measurement circuit; the voltage measurement circuit includes a first fuse, a second fuse, and a voltmeter; one end of the first fuse is connected to L1 in the three-phase power supply; one end of the second fuse is connected to L2 in the three-phase power supply; the other end of the first fuse is connected in series with the other end of the voltmeter and the second fuse.
[0014] According to the specific embodiments provided by this utility model, the following technical effects are disclosed: This invention integrates a safety module, a height acquisition module, and a soft measurement module. The system can monitor the crane's operating status and cargo swaying in real time. Using mathematical models and variable frequency speed control technology, it precisely adjusts the motor speed, effectively suppressing the swaying of the hook and cargo. The soft measurement module, with its microprocessor, sampling and conditioning circuit, and signal isolation and conversion circuit, accurately processes signals from the grating encoder and rotary transformer, ensuring the accuracy and response speed of the anti-sway control. This invention integrates multiple functional modules into the control system, simplifying the system structure, reducing external wiring, lowering maintenance complexity, and utilizing the high-performance processing capabilities of the microprocessor to implement complex control algorithms and real-time data processing, thus improving the system's intelligence level. Attached Figure Description
[0015] 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 only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0016] The following description, in conjunction with the accompanying drawings, further illustrates the high-efficiency and energy-saving integrated crane control system of this utility model; Figure 1 This is a schematic diagram of the circuit structure of the crane control circuit in this utility model; Figure 2 This is a schematic diagram illustrating the connection principle of the various modules of the intelligent swing system in this utility model; Figure 3 This is a schematic diagram of the control system in the intelligent swing system of this utility model; Figure 4 This is a basic architecture diagram of the microprocessor in the control system of this utility model; Figure 5 This is a force analysis diagram of the motor anti-swaying mechanism in this utility model. Detailed Implementation
[0017] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.
[0018] To better understand the purpose, structure, and function of this utility model, a more detailed description of this utility model is provided below with reference to the accompanying drawings. Example 1
[0019] This utility model provides a high-efficiency and energy-saving integrated crane control system, including: Intelligent anti-sway system and frequency converter; The intelligent anti-sway system includes: a safety module, a height acquisition module, a soft measurement module, and a main control module; In this embodiment, as Figure 2 The diagram illustrates how soft-sensor technology detects the swing angle. Using the estimated swing angle and a specific mathematical model, the inverter's output and frequency are adjusted to control the actual operating speed of the mechanism, thereby suppressing hook sway. As a novel anti-sway measure, the electronic anti-sway system achieves automatic control, reducing manual operation, and with further development, could potentially achieve unmanned operation.
[0020] Furthermore, through the fundamental functions of frequency converters, soft start and soft stop functions of cranes can be achieved, thereby reducing the impact force on the crane during start-up and shutdown operations, protecting the crane's structure from damage, and ensuring the stability of its various performance characteristics. At the same time, because the speed regulation range of frequency conversion speed regulation technology is relatively wide, and frequency converters mainly use a modular design approach in the design process, and are controlled by PLC technology, different speeds can be controlled and selected, thus achieving stepless speed regulation during operation, ensuring good performance indicators, and greatly reducing the risk of falling due to swaying during object movement.
[0021] The intelligent anti-sway system in this embodiment monitors the hook swing length-related speed parameter v_m and height information (acquired by the safety module and height acquisition module) in real time. The soft measurement module, combined with the anti-sway process algorithm, calculates a control signal, which is then adjusted by the frequency converter to control the motor speed, thereby adjusting the running speed v_0 of the trolley / gantry actuator and dynamically suppressing hook sway. Simultaneously, the system communicates with... Figure 3 and Figure 4 The interconnection of microprocessors in the system enables the microprocessor to integrate anti-sway control signals with internal algorithms (such as motor vector control), and work with modules such as FPGA / CPLD to perform global control of frequency converters, actuators and external circuits (such as PGA411 and DA modules), ultimately achieving integrated control of safe operation, precise positioning and efficient anti-sway of the crane.
[0022] The control signals calculated by the soft measurement module in the anti-sway system are transmitted to the system via digital interfaces (such as SPI, GPIO, etc.). Figure 3 and Figure 4 The microprocessor shown is a DSP. Based on the received anti-sway system control signal and its own control algorithm, the microprocessor further precisely controls the frequency converter and other actuators to achieve coordinated operation of the entire crane control system and ensure the coordinated operation of the anti-sway function and other control functions.
[0023] like Figure 3 As shown, the main control module includes: a microprocessor, a sampling conditioning circuit, a grating encoder signal isolation and conversion circuit, a resolver filter and decoding circuit, and a DA output circuit; The safety module and the altitude acquisition module are respectively connected to the soft measurement module; the soft measurement module is connected to the microprocessor via a digital interface; A major highlight of the all-digital multi-to-multi control technology in this embodiment is the precise synchronous control of multiple transmission components by a single control system. By integrating an advanced digital signal processor and a programmable logic control system, the system can receive and analyze high-precision data from various sensors in real time, thereby precisely controlling multiple transmission components such as motors and hydraulic motors on the crane. This multi-to-multi control method not only significantly improves the crane's working efficiency but also enables the crane to easily handle various complex working conditions, such as heavy-load lifting and rapid positioning, thus meeting diverse operational needs. Another major highlight of the all-digital multi-to-multi control technology is its excellent flexibility and scalability. The powerful processing capabilities of digital signals mean that whether a single crane is performing a single task or multiple cranes are working collaboratively, the system can provide stable and reliable control support. Furthermore, with continuous technological advancements, the all-digital multi-to-multi control system can continuously expand its functions through software upgrades, thereby further enhancing the crane's intelligence level. This flexible and scalable control method lays a solid foundation for the future development of intelligent multi-purpose cranes.
[0024] The sampling and conditioning circuit is connected to the microprocessor via an AD interface; the grating encoder signal isolation and conversion circuit is connected to the microprocessor via a GPIO interface; the resolver filter and decoding circuit is connected to the microprocessor via a first SPI interface; the microprocessor is connected to a DA output circuit via a second SPI interface; the DA output circuit is connected to the frequency converter, and the output port of the frequency converter is connected to the input terminals of the first, second, and third motors in the main circuit of the crane, respectively. By adjusting the motor speed, and with its output port connected to the motor input terminal, the frequency converter can change the output frequency and voltage according to the control signal to achieve motor speed regulation, thereby meeting different lifting and running speed requirements.
[0025] In this embodiment, the sampling conditioning circuit uses an OPA277 high-precision operational amplifier to amplify the weak signal, and combines it with a second-order active low-pass filter circuit to filter out high-frequency noise. The conditioned analog signal is then transmitted to the microprocessor for digital processing via the ADC interface. The grating encoder signal isolation and conversion circuit achieves electrical isolation through a 6N137 high-speed optocoupler, uses an AMC1301 chip to convert differential signals to single-ended signals, and finally transmits position and speed information to multiple motors through the GPIO interface.
[0026] The resolver filtering and decoding circuit uses an LC filter circuit to suppress high-frequency harmonic interference and relies on the AD2S1210 dedicated decoding chip to convert the resolver output signal into digital angle information. It provides high-precision rotor position data to the microprocessor through SPI or parallel interface, thereby constructing a complete sensor signal acquisition and processing link.
[0027] The main control module adopts a DSP+FPAG+CPLD architecture; The DSP and FPAG are connected via a serial data exchange interface; the CPLD is connected to the DSP via a first serial communication interface; and the CPLD is connected to the FPAG via a second serial communication interface.
[0028] In this embodiment, the main control module adopts a DSP+FPAG+CPLD architecture. The DSP28377D has a high main frequency and fast data processing speed. It is paired with FPAG and CPLD as the core main control board, with complete protection functions. With the help of various expansion boards, it can meet the requirements of high dynamic performance, fast protection and intelligent networking in crane operation.
[0029] like Figure 3 and Figure 4 In the illustrated modules, the DSP, acting as a microprocessor, handles complex digital signal processing and control algorithms (such as motor vector control). It interacts with the FPGA via the EMIF interface and connects to external circuits (such as the PGA411) through interfaces like SPI and GPIO to achieve sensor data acquisition and control signal output. The FPGA, leveraging its high-speed parallel processing capabilities, is responsible for multi-channel signal timing control, data buffering, and simple algorithm logic. It communicates with peripherals such as AD / DA conversion modules and the 1553B bus via I / O interfaces and collaborates with the DSP to complete system functions. The CPLD focuses on simple logic and timing control (such as LED display and relay driving). It connects to external execution modules via I / O interfaces and interconnects with modules like the FPGA to achieve system logic collaboration. Furthermore, an 8-channel DA output module converts digital signals into analog quantities to control external devices and connects to the FPGA / DSP via digital interfaces. The PGA411, as a programmable gain amplifier, receives DSP commands via the SPI interface to dynamically adjust signal gain, improving the system's signal conditioning and control chain. Ultimately, this constructs a highly efficient digital processing and control architecture with the DSP at its core and the FPGA and CPLD working in collaboration.
[0030] In this crane control system, the main control module adopts a DSP + FPGA + CPLD architecture. Typically, the DSP (Digital Signal Processor) is mainly used for high-speed digital signal processing; the FPGA (Field-Programmable Gate Array) has high flexibility and parallel processing capabilities, and can be used to implement various logic functions; the CPLD (Complex Programmable Logic Device) is suitable for implementing simple combinational and sequential logic. The DSP can connect to the FPGA via data bus, address bus, etc., transmitting data requiring parallel processing or logic control to the FPGA. After processing the data according to preset logic, the FPGA can feed back the processing results to the DSP or transmit control signals to the CPLD. The CPLD then implements specific logic control functions based on the received signals. In this system, the three components are interconnected and communicate through an internal bus or specific interface circuits to collaboratively complete the main control module's control tasks for the entire crane control system.
[0031] The main circuit of the crane includes: a three-phase power supply, a first circuit breaker, a second circuit breaker, a third circuit breaker, a fourth circuit breaker, a first AC contactor, a second AC contactor, a third AC contactor, a fourth AC contactor, a fifth AC contactor, a sixth AC contactor, a first thermal relay, a second thermal relay, a third thermal relay, a soft starter, a first motor, a second motor, and a third motor; The input terminals of the first, second, third, and fourth circuit breakers are respectively connected to L1, L2, and L3 of the three-phase power supply; the output terminal of the first circuit breaker is connected to the power input terminal of the soft starter; the output terminal of the second circuit breaker is connected to the input terminal of the second AC contactor; the output terminal of the third circuit breaker is connected to the input terminal of the fourth AC contactor; the output terminal of the fourth circuit breaker is connected to the input terminal of the sixth AC contactor; the power output terminal of the soft starter is respectively connected to the input terminals of the first, third, and fifth AC contactors; the output terminal of the second AC contactor is connected to the input terminal of the first thermal relay; the output terminal of the fourth AC contactor is connected to the input terminal of the second thermal relay; the output terminal of the sixth AC contactor is connected to the input terminal of the third thermal relay; the output terminals of the first AC contactor and the first thermal relay are jointly connected to the terminals of the first motor; the output terminals of the third AC contactor and the second thermal relay are jointly connected to the terminals of the second motor; the output terminals of the fifth AC contactor and the third thermal relay are jointly connected to the terminals of the third motor. The main control module includes: an external switch control input circuit, a motor status indication circuit, and a PWM drive fault return circuit; The external switch control input circuit is connected to the microprocessor through the first I / O interface; The 24-channel PWM drive fault return circuit is connected to the microprocessor through the second I / O interface; In this embodiment, the 24-channel PWM drive fault return circuit includes signal detection elements (such as current sensors and voltage sensors, used to detect abnormalities in parameters such as current and voltage in the PWM drive circuit), signal processing elements (such as operational amplifiers, used to amplify and shape the detected signals), and signal transmission elements (such as optocouplers, used to isolate and transmit the processed fault signal to the microprocessor). The specific connection is as follows: the signal detection elements are connected to key nodes in the PWM drive circuit (such as the output of the power transistor) to detect relevant parameters in real time; the detected signals are transmitted to the signal processing elements for processing; the processed signals are transmitted to the microprocessor via the signal transmission elements (such as optocouplers) through the second I / O interface, enabling the microprocessor to promptly obtain the fault status of the PWM drive circuit and respond accordingly.
[0032] The motor status indication circuit is connected to the microprocessor via a third I / O interface.
[0033] In this embodiment, three-phase power supplies L1, L2, and L3 serve as inputs, and circuit breakers QF1-QF4 provide on / off control and short-circuit protection. The soft starter STRB is connected to the power supply via QF1, and its output is connected to motor M1 via the main contacts of contactor KM1. Smooth motor starting is achieved through thyristor conduction angle control, reducing starting current surges. It also includes RUN / STOP / COM control terminals and "start complete" and "fault" status feedback interfaces. KM2 switches to full-voltage power supply after soft starting, and KM4 and KM5 control the motor circuits of M2 and M3, respectively. Thermal relays FR1-FR3 are connected in series in the main circuit of each motor. Overheating deformation of the bimetallic strip triggers contactor de-energization, providing overload protection. Current transformers LH1-LH3, along with ammeters PA1-PA3, monitor motor current in real time, while fuses FU1-FU2 provide short-circuit protection for voltmeter PV, used to measure three-phase line voltage. The entire system uses contactor electromagnetic coil on / off control and multi-layer protection devices to ensure motor start-stop safety and visualize its operating status.
[0034] The motor control system employs a combination of soft start and full-voltage operation. Taking motor M1 as an example: after closing circuit breaker QF1, the soft starter's RUN / STOP terminal controls its slow start. Once the soft starter outputs a "start complete" signal, contactor KM2 engages, switching to full-voltage operation at the power frequency and disconnecting KM1. M2 and M3 achieve similar start-stop control through their corresponding contactors (KM4 and KM5). The system is equipped with multiple protection devices: thermal relays FR1-FR3 provide overload protection by cutting off the control circuit to de-energize the contactors; circuit breakers QF1-QF4 provide short-circuit and severe overload protection; and fuses FU1-FU2 are specifically designed for short-circuit protection of the voltmeter PV, forming a hierarchical protection system.
[0035] In summary, compared to traditional cranes, this embodiment incorporates a frequency converter with an embedded intelligent anti-sway system, making objects safer during movement. It also integrates precise voice operation and gesture recognition technology, as well as fully digital one-to-many control technology, further expanding application areas, improving crane operating efficiency and accuracy, and making it more green and energy-efficient.
[0036] The main control module also includes a PWM hardware logic protection output circuit and a seven-segment digital tube status display; The PWM hardware logic protection output circuit is connected to the microprocessor through 12 groups of 24-channel PWM interfaces. The seven-segment display is connected to the microprocessor via the fourth I / O interface to display the motor status.
[0037] In this embodiment, the PWM hardware logic protection output circuit in the main circuit primarily serves to provide hardware logic protection for the output signal. Considering its function, it can be connected between the microprocessor and the power drive section of the main circuit (such as the control signal input point related to power conversion devices like frequency converters). For example, the PWM control signal output from the microprocessor first undergoes logic judgment and protection processing through the PWM hardware logic protection output circuit, and then the processed signal is transmitted to the power control components in the main circuit (such as the control signal input terminal of the frequency converter) to ensure that the power components in the main circuit operate under correct and safe PWM signal control.
[0038] The external switch control input circuit specifically comprises: the coils of the first AC contactor, the third AC contactor, and the fifth AC contactor connected in parallel; one end of each coil is connected to the RUN port of the soft starter; the other end of each coil is connected to the COM port of the soft starter; and the STOP port of the soft starter is connected to the COM port via a normally closed stop button.
[0039] The main circuit of the first motor is equipped with a first current transformer, and the first current transformer is connected in series with a first ammeter; the main circuit of the second motor is equipped with a second current transformer, and the second current transformer is connected in series with a second ammeter; the main circuit of the third motor is equipped with a third current transformer, and the third current transformer is connected in series with a third ammeter.
[0040] The three-phase power supply is equipped with a voltage measurement circuit; the voltage measurement circuit includes a first fuse, a second fuse, and a voltmeter; one end of the first fuse is connected to L1 in the three-phase power supply; one end of the second fuse is connected to L2 in the three-phase power supply; the other end of the first fuse is connected in series with the other end of the voltmeter and the second fuse. Example 2
[0041] This utility model further provides a crane control algorithm: Dynamically adjusting motor speed and torque ensures the resultant force aligns with the direction of motion. A linear function is incorporated during startup and shutdown. During startup, speed and torque are gradually increased using the linear functions ω(t) = ωmax·t / Tstart and τ(t) = τmax·t / Tstart. During shutdown, deceleration is smoothed using ω(t) = ωmax·(1−t / Tstop), thereby reducing mechanical shock and preventing force fluctuations. The smooth changes in speed and current data in the graph demonstrate its effectiveness. This control strategy results in more uniform motor output, prevents significant fluctuations in force direction and magnitude, and avoids crane swaying caused by improper motor control. It contributes to improving the stability and reliability of crane operation. Working in conjunction with intelligent anti-sway systems and variable frequency speed control technology, it ensures efficient and safe crane operation.
[0042] like Figure 5 As shown, the anti-sway system in this invention monitors the hook swing length-related speed parameter v_m and height information (obtained by the safety module and height acquisition module) in real time. The soft measurement module calculates the control signal based on the anti-sway process algorithm, and the inverter adjusts the output frequency f to control the motor speed, thereby adjusting the running speed v_0 of the trolley / crane actuator and dynamically suppressing the hook swing. At the same time, the system is interconnected with the DSP controller through digital interfaces such as SPI / GPIO, enabling the DSP to integrate the anti-sway control signal with internal algorithms (such as motor vector control), and coordinate with modules such as FPGA / CPLD to perform global control of the inverter, actuator and external circuits (such as PGA411 and DA modules), ultimately achieving integrated control of safe crane operation, accurate positioning and efficient anti-sway.
[0043] The control signals calculated by the soft measurement module in this anti-sway system are transmitted to [the relevant entity] via digital interfaces (such as SPI, GPIO, etc.). Figure 3 and Figure 4 The main control module (DSP) in the system. Based on the received anti-sway system control signals and its own control algorithm, the main control module further performs precise control on the frequency converter and other actuators to achieve coordinated operation of the entire crane control system and ensure the coordinated work of the anti-sway function and other control functions.
[0044] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A high-efficiency, energy-saving integrated crane control system, characterized in that, include: Intelligent anti-sway system and frequency converter; The intelligent anti-sway system includes: a safety module, a height acquisition module, a soft measurement module, and a main control module; The main control module includes: a microprocessor, a sampling and conditioning circuit, a grating encoder signal isolation and conversion circuit, a resolver filter and decoding circuit, and a DA output circuit; The safety module and the altitude acquisition module are respectively connected to the soft measurement module; the soft measurement module is connected to the microprocessor via a digital interface; The sampling and conditioning circuit is connected to the microprocessor via an AD interface; the grating encoder signal isolation and conversion circuit is connected to the microprocessor via a GPIO interface; the resolver filter and decoding circuit is connected to the microprocessor via a first SPI interface; the microprocessor is connected to the DA output circuit via a second SPI interface; the DA output circuit is connected to the frequency converter, and the output port of the frequency converter is connected to the input terminals of the first motor, the second motor, and the third motor in the main circuit of the crane, respectively.
2. The high-efficiency energy-saving integrated crane control system according to claim 1, characterized in that, The main control module adopts a DSP+FPAG+CPLD architecture; The DSP and FPAG are connected via a serial data exchange interface; the CPLD is connected to the DSP via a first serial communication interface; and the CPLD is connected to the FPAG via a second serial communication interface.
3. The high-efficiency energy-saving integrated crane control system according to claim 1, characterized in that, The digital interfaces include: SPI interface and GPIO interface.
4. The high-efficiency energy-saving integrated crane control system according to claim 1, characterized in that, The main circuit of the crane includes: a three-phase power supply, a first circuit breaker, a second circuit breaker, a third circuit breaker, a fourth circuit breaker, a first AC contactor, a second AC contactor, a third AC contactor, a fourth AC contactor, a fifth AC contactor, a sixth AC contactor, a first thermal relay, a second thermal relay, a third thermal relay, a soft starter, a first motor, a second motor, and a third motor; The input terminals of the first, second, third, and fourth circuit breakers are respectively connected to L1, L2, and L3 of the three-phase power supply; the output terminal of the first circuit breaker is connected to the power input terminal of the soft starter; the output terminal of the second circuit breaker is connected to the input terminal of the second AC contactor; the output terminal of the third circuit breaker is connected to the input terminal of the fourth AC contactor; the output terminal of the fourth circuit breaker is connected to the input terminal of the sixth AC contactor; the power output terminal of the soft starter is respectively connected to the input terminals of the first, third, and fifth AC contactors; the output terminal of the second AC contactor is connected to the input terminal of the first thermal relay; the output terminal of the fourth AC contactor is connected to the input terminal of the second thermal relay; the output terminal of the sixth AC contactor is connected to the input terminal of the third thermal relay; the output terminals of the first AC contactor and the first thermal relay are jointly connected to the terminals of the first motor; the output terminals of the third AC contactor and the second thermal relay are jointly connected to the terminals of the second motor; the output terminals of the fifth AC contactor and the third thermal relay are jointly connected to the terminals of the third motor.
5. The high-efficiency energy-saving integrated crane control system according to claim 1, characterized in that, The main control module includes a PWM hardware logic protection output circuit and a seven-segment digital tube status display; The PWM hardware logic protection output circuit is connected to the microprocessor through 12 groups of 24-channel PWM interfaces. The seven-segment display is connected to the microprocessor via the fourth I / O interface to display the motor status.
6. The high-efficiency energy-saving integrated crane control system according to claim 4, characterized in that, The main control module also includes: an external switch control input circuit, a motor status indication circuit, a PWM drive fault return circuit, and a 24-channel PWM drive fault return circuit; The external switch control input circuit is connected to the microprocessor through the first I / O interface; The 24-channel PWM drive fault return circuit is connected to the microprocessor through the second I / O interface; The motor status indication circuit is connected to the microprocessor via a third I / O interface.
7. The high-efficiency energy-saving integrated crane control system according to claim 6, characterized in that, The external switch control input circuit specifically comprises: the coils of the first AC contactor, the third AC contactor, and the fifth AC contactor connected in parallel; one end of each coil is connected to the RUN port of the soft starter; the other end of each coil is connected to the COM port of the soft starter; and the STOP port of the soft starter is connected to the COM port via a normally closed stop button.
8. The high-efficiency energy-saving integrated crane control system according to claim 4, characterized in that, The main circuit of the first motor is equipped with a first current transformer, and the first current transformer is connected in series with a first ammeter; the main circuit of the second motor is equipped with a second current transformer, and the second current transformer is connected in series with a second ammeter; the main circuit of the third motor is equipped with a third current transformer, and the third current transformer is connected in series with a third ammeter.
9. The high-efficiency energy-saving integrated crane control system according to claim 4, characterized in that, The three-phase power supply is equipped with a voltage measurement circuit; the voltage measurement circuit includes a first fuse, a second fuse, and a voltmeter; one end of the first fuse is connected to L1 in the three-phase power supply; one end of the second fuse is connected to L2 in the three-phase power supply; the other end of the first fuse is connected in series with the other end of the voltmeter and the second fuse.