Aerial crane skill competition collision counting system

Abstract

The utility model discloses a kind of overhead crane skill competition collision counting systems, including power module, PLC control module, communication module, display module, sensor module, functional unit, operating box. PLC control module is connected display module and the contact sensor for detecting collision by cable;Control system module is connected with communication module through backplane bus;Counting display module includes nixie tube display and is connected with communication module by RS485 cable;Self-resetting button is connected with PLC control module by cable;State indicating lamp is shown system operating state by relay receiving PLC control module signal;Contact sensor is connected with PLC control module by cable, and collision state is transmitted to PLC control module;Functional unit includes start / reset physical button, pause physical button, RS485 communication interface. With the characteristics of adjustable parameter, portable reliable, can effectively improve competition fairness.

Description

Technical Field

[0001] This utility model belongs to the field of competition equipment technology, and relates to a high-precision collision counting system based on PLC control, which is used for automatic collision detection and real-time display of results in crane operation competitions. Background Technology

[0002] Traditional overhead crane skills competitions rely on manual observation of collision counts to determine the winner, lacking a real-time results display system. This results in poor accuracy, strong subjectivity, and low transparency. Existing anti-collision devices also fail to effectively address the accuracy issue due to misjudgments caused by material elastic vibrations.

[0003] Chinese patent CN217708614U provides a crane anti-collision device that achieves anti-collision detection within a 3L range from the center point of the low-span crane by applying a laser detection switch above the end beam of the low-span crane, but it is not designed for competition counting requirements. Utility Model Content

[0004] This invention aims to provide a collision counting system for overhead crane skill competitions, which can display the competition process in real time and improve the transparency of the competition; the parameters are adjustable to adapt to various competition events; the response speed is in the millisecond level and the error rate is ≤0.5%; the modular design facilitates promotion and use.

[0005] Technical solution of utility model: A collision counting system for overhead crane skill competitions, characterized by comprising a power supply module, a PLC control module, a communication module, a display module, a sensor module, functional units, and an operation box; the power supply module supplies power to the PLC controller and all modules; the PLC control module is connected to the display module and a contact sensor for detecting collisions via cables; the control system module is connected to the communication module via a backplane bus; the counting display module includes a digital tube display connected to the communication module via an RS485 cable; a self-reset button is connected to the PLC control module via a cable; status indicator lights receive signals from the PLC control module via relays to display the system's operating status; the contact sensor is connected to the PLC control module via cables to transmit the collision status to the PLC control module; the functional units include a start / reset physical button, a pause physical button, and an RS485 communication interface.

[0006] The sensor module includes a sensor and a signal conditioning circuit. The sensor is a high-sensitivity contact current loop sensor, which is installed on the hanging platform and at obstacle points. The signal conditioning circuit is used to filter out electromagnetic interference.

[0007] The display module includes a digital tube display connected to the communication module via an RS485 cable, a self-reset button connected to the PLC control module via a cable, a status indicator light receiving signals from the PLC control module via a relay to display the system's operating status, and a MODBUS digital tube displaying the remaining number of collisions in real time.

[0008] The functional units include: a count reset button, an auto / pause button, a count run indicator light, a count reset indicator light, and a contact sensor. The count reset button and auto / pause button are connected to the PLC DI interface via cables. The PLC runs the crane collision counting program and controls the count run indicator light and count reset indicator light via relays to display the program's running status. The contact sensor is connected to the PLC controller DI interface via a cable. The digital tube display module is connected to the PLC controller via RS485. The indicator light and button controls are connected to the relay control via the PLC controller's DI and DO interface cables.

[0009] In one specific embodiment, the PLC control module adopts a Siemens S7-1200 PLC, and the communication module adopts a CM1241 RS422 / 485; the time display and the count display are digital tube displays and are connected to the PLC via the MODBUS RTU protocol.

[0010] The entire counting system hardware is fixed on an operating box with guide rails.

[0011] The beneficial effects of this utility model are: millisecond-level response speed, error rate ≤0.5%; real-time display improves competition transparency; adjustable parameters adaptable to various competition projects; modular design facilitates widespread use. Attached Figure Description

[0012] Figure 1 This is a diagram of the collision counting system architecture for overhead crane racing.

[0013] Figure 2 This is a flowchart of the filtering program for the overhead crane collision counting system.

[0014] Figure 3 This is a circuit diagram for a crane collision counting system.

[0015] In the diagram: U1 - Power module; A2 - PLC control module; A1 - Communication module; U - Display module package; U2 - Timer display; U3 - Count display; S6 - Start button; S5 - Reset button; S3 - Collision sensor; K1 - Running light relay; K2 - Reset light relay; K3 - Counting terminal relay; H1 - Counting running indicator; H2 - Counting reset indicator. Detailed Implementation

[0016] The following description, in conjunction with the accompanying drawings, illustrates the embodiments.

[0017] Figure 1 , Figure 3 The overhead crane collision counting system, as shown, comprises a power supply module U1, a PLC control module A2, a communication module A1, a timing display U2, a timing count display U3, a collision sensor S3, a reset button S5, a start button S6, and an operation box. The power supply module U1 is a Mean Well DR-60-24 switching power supply module; the PLC control module A2 is a SIEMENS SS7-1200 PLC; the communication module A1 is a SIEMENS RS422 / 485 communication module; the display modules include the timing display U2 and the counting count display U3; and the functional modules include the start button S6, the reset button S5, the collision sensor S3, the running light relay K1, the reset light relay K2, the counting terminal relay K3, the counting running indicator H1, and the counting reset indicator H2.

[0018] The sensor module includes a sensor and a signal conditioning circuit. The sensor is a high-sensitivity contact current loop sensor, which is installed on the hanging platform and at obstacle points. The signal conditioning circuit is used to filter out electromagnetic interference.

[0019] The display module includes digital tube displays U2 and U3, which are connected to the communication module A1 via an RS485 cable. The reset button S5 is connected to the PLC control module A2 via a cable. The status indicator lights H1 and H2 receive signals from the PLC control module A1 via relays to display the system's operating status. The MODBUS digital tube U3 displays the remaining number of collisions in real time, and U2 displays the timing time in real time.

[0020] The functional unit includes a count reset button S5, an auto / pause button S6, a count run indicator H1, a count reset indicator H2, and a contact sensor S3. The count reset button S5 and the auto / pause button S6 are connected to the PLC (A2) DI interface via cables. The overhead crane collision counting program is run, and the count run indicator H1 and the count reset indicator H2 are controlled by relays K3 and K2 respectively to display the running status. The collision sensor S3 is connected to the PLC controller (A2) DI interface via a cable.

[0021] The PLC control module uses Siemens S7-1200PLC A2, and the communication module uses CM1241 RS422 / 485A1; the display modules U2 and U3 communicate with PLC A2 via MODBUS RTU protocol.

[0022] The entire counting system hardware is fixed on an operating box with guide rails.

[0023] During operation, the power supply module supplies power to the PLC controller; the PLC control module A2 is connected to the display module and the contact sensor for collision detection via cables; the PLC control module A2 is connected to the communication module A1 via the backplane bus; the display module includes two digital tube displays U2 and U3 connected to the communication module via RS485 cables; the K1 and K2 status indicator lights receive signals from the PLC control module A2 via relays to display the system operating status; the collision sensor S3 is connected to the PLC control module A2 via cables to transmit the collision status to the PLC control module A2; the start button S6 and the reset button S5 are connected to the PLC control module A2 via cables.

[0024] The system can automatically time and count the collision results of overhead crane races, and the timing and scoring methods can be freely set in the PLC program. The system is fixed on an operating box with guide rails.

[0025] Figure 2 As shown: Taking the bucket-on-pole race as an example, the working process steps are as follows: 1) Initialization: Press the reset button first. The timer and count will display the preset values ​​(900 seconds and 100 times) and the reset buzzer will sound three times in a row.

[0026] 2) Operation: Press the start button to begin the countdown. The counter will automatically decrement by 1 each time the disc touches the frame (only one count per second). If the disc touches the frame continuously for a long time, the counter will decrement cumulatively (1 decrement per second). Both functions are active simultaneously.

[0027] 3) Special case handling: Elastic rod vibration: Multiple contacts within 1 second will only be counted once; Continuous pressing of an obstacle: Automatically decreases by 1 second after 1 second; Timer pause: If the timer is not 0, pressing the start button will pause the timer, and pressing the start button again will resume the timer.

[0028] 4) Results Recording: Data is exported via RS485 after the competition ends.

Claims

1. A collision counting system for overhead crane skill competitions, characterized in that: It includes a power supply module, a PLC control module, a communication module, a display module, a sensor module, functional units, and an operation box. The power supply module supplies power to the PLC controller and all modules. The PLC control module is connected to the display module and a contact sensor for collision detection via cables. The control system module is connected to the communication module via a backplane bus. The counting display module, including a digital tube display, is connected to the communication module via an RS485 cable. The self-reset button is connected to the PLC control module via a cable. Status indicator lights receive signals from the PLC control module via relays to display the system's operating status. The contact sensor is connected to the PLC control module via cables to transmit collision status to the PLC control module. The functional units include a start / reset physical button, a pause physical button, and an RS485 communication interface.

2. The collision counting system for overhead crane skill competitions according to claim 1, characterized in that: The sensor module includes a sensor and a signal conditioning circuit. The sensor is a high-sensitivity contact current loop sensor, which is installed on the hanging platform and at the obstacle point. The signal conditioning circuit is used to filter out electromagnetic interference.

3. The collision counting system for overhead crane skill competitions according to claim 1, characterized in that: The display module includes a digital tube display connected to the communication module via an RS485 cable, a self-reset button connected to the PLC control module via a cable, a status indicator light receiving signals from the PLC control module via a relay to display the system's operating status, and a MODBUS digital tube displaying the remaining number of collisions in real time.

4. The collision counting system for overhead crane skill competitions according to claim 1, characterized in that: The functional unit includes a count reset button, an auto / pause button, a count run indicator light, a count reset indicator light, and a contact sensor. The count reset button and auto / pause button are connected to the PLC DI interface via cables. The PLC runs the overhead crane collision counting, and the count run indicator light and count reset indicator light are controlled by relays to display the running status. The contact sensor is connected to the PLC controller DI interface via a cable. The digital tube display module is connected to the PLC controller via RS485. The indicator light and button controls are connected to the relay control via the PLC controller DI and DO interface cables.

5. The collision counting system for overhead crane skill competitions according to claim 1, characterized in that: The PLC control module uses a Siemens S7-1200 PLC, and the communication module uses a CM1241 RS422 / 485. The timer and count display are digital tube displays and are connected to the PLC via the MODBUS RTU protocol.

6. The collision counting system for overhead crane skill competitions according to claim 1, characterized in that: The entire counting system hardware is fixed on an operating box with guide rails.

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