Bridge crane detection and counting circuit

Abstract

The utility model relates to the field of crane, concretely relates to a bridge crane detection statistics circuit. Bridge crane includes respectively control upper, lower, east, west, south, north walking's upper, lower, east, west, south, north contactor, bridge crane detection statistics circuit includes intermediate relay K1~K6, controller and with intermediate relay one -to -one corresponding photoelectric coupler isolation unit, every intermediate relay, its coil connects the power supply circuit of corresponding contactor's coil, to with corresponding contactor's coil synchronous power -on, its switch connects corresponding photoelectric coupler isolation unit, every photoelectric coupler isolation unit connects the input of controller, the intermediate relay is configured as, when its coil power -on, through its switch switching makes corresponding photoelectric coupler isolation unit trigger the controller statistics operation duration. The utility model can accurately statistics each direction motor's operation duration and the pulling work duration of steel cable, provides the basis for the motor, steel cable maintenance life.

Description

Technical Field

[0001] This utility model relates to the field of cranes, specifically to a detection and statistical circuit for bridge cranes. Background Technology

[0002] In the field of industrial hoisting, bridge cranes save space by relying on factory columns or rails for support, resulting in a lower unit price. They also operate stably, have high main beam rigidity, minimal swaying during hoisting, are suitable for precise positioning, and have advantages such as low overall energy consumption, low operating costs, and convenient maintenance. They are now widely used in mechanical manufacturing workshops, high-precision assembly, mass production, indoor warehousing and other scenarios.

[0003] Overhead cranes, due to their high load capacity and frequent use, have motors in all directions and hoisting cables operating for extended periods, making them the components most in need of maintenance. For example, the cables require regular inspection and maintenance, lubricating at least once every 200 working hours or once a month. They must be replaced when more than two wires break within a single twist or when the total number of broken wires exceeds 10%. Cables exhibiting "lantern-shaped" deformation or localized flattening exceeding 5% of their diameter must be immediately scrapped.

[0004] However, existing overhead cranes cannot provide real-time statistics on the detailed usage of the crane's motors and cables. They can only refer to data from the last manual maintenance or rely on expensive cable detectors. Some manufacturers install several overhead cranes, but not all of them are used frequently. Regardless of whether the crane is currently in use, each maintenance inspection requires production to be stopped, relying entirely on regular manual inspections. This results in low production efficiency and is highly incompatible with the production needs of modern enterprises.

[0005] Therefore, it is essential to monitor and statistically analyze the actual pulling time of the upper and lower steel cables of the bridge crane, the travel time of the east and west hoist motors, and the travel time of the north and south main motors, so as to provide accurate data support for the company's maintenance and repair. Summary of the Invention

[0006] The technical problem to be solved by this utility model is to overcome the defects of the prior art and provide a detection and statistics circuit for a bridge crane. It can accurately count the running time of the motors in each direction and the pulling time of the steel cables, providing a basis for the maintenance life of the motors and steel cables.

[0007] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows: a detection and statistical circuit for a bridge crane, wherein the bridge crane includes upper, lower, east, west, south, and north contactors respectively controlling the upper, lower, east, west, south, and north movement; the bridge crane detection and statistical circuit includes intermediate relays K1~K6, a controller, and optocoupler isolation units corresponding to each intermediate relay; wherein, Each intermediate relay has its coil connected to the power supply circuit of the corresponding contactor coil so as to be energized synchronously with the coil of the corresponding contactor, and its switch is connected to the corresponding optocoupler isolation unit. Each optocoupler isolation unit is connected to one input terminal of the controller. The intermediate relay is configured to, when its coil is energized, switch to trigger the corresponding optocoupler isolation unit to count the operating time of the controller.

[0008] Furthermore, the bridge crane detection and statistics circuit also includes several limit switches connected to the controller, used to detect whether the bridge crane has reached its limit position in the east, west, north, and south directions.

[0009] Furthermore, the bridge crane detection and statistics circuit also includes a weight sensor connected to the controller for detecting the lifting weight of the bridge crane.

[0010] Furthermore, the bridge crane detection and statistics circuit also includes a motor encoder, connected to the controller, for detecting the actual height of the bridge crane's hook.

[0011] Furthermore, for each intermediate relay, its coil is connected in parallel with the corresponding contactor coil, one contact of its normally closed switch is grounded, and the other contact is connected to the positive terminal of the power supply and one end of the transmitter of the optocoupler isolation unit, respectively, while the other end of the transmitter of the optocoupler isolation unit is grounded; One end of the receiving end of the optocoupler isolation unit is connected to one input terminal of the controller and is also connected to the positive terminal of the power supply through a resistor, while the other end is grounded.

[0012] Furthermore, the bridge crane detection and statistics circuit also includes an indicator unit corresponding to each of the contactors, used to provide an indication when the corresponding contactor controls the bridge crane to travel in the corresponding direction.

[0013] Furthermore, the indicator unit includes a light-emitting diode (LED), the anode of which is connected to the positive terminal of the power supply via a resistor, and the cathode is connected to one end of the receiving end of the corresponding optocoupler isolation unit of the contactor.

[0014] Furthermore, the bridge crane detection and statistics circuit also includes a controlled power supply unit, comprising transistor Q2, MOSFET Q1, and power output port J11; wherein, The base of transistor Q2 is connected to the controller, the collector is connected to a positive power supply through resistor R35, and is also connected to the gate of MOSFET Q1 through resistor R36. The emitter is grounded. The source of MOSFET Q1 is connected to the positive terminal of the power supply, the drain is connected to terminal 1 of the power output port, and terminal 2 of the power output port is grounded.

[0015] Furthermore, terminal 3 of the power output port is connected to a positive power supply.

[0016] Furthermore, the bridge crane detection and statistics circuit also includes a controlled switch relay unit, comprising transistor Q4 and relay K7; wherein, The base of transistor Q4 is connected to the controller, and the collector is connected to one end of the coil of relay K7. The transmitter is grounded. The other end of the coil of relay K7 is connected to a positive power supply.

[0017] By adopting the above technical solution, this utility model can accurately calculate the running time of motors in each direction and the pulling time of steel cables, providing a basis for the maintenance life of motors and steel cables, as well as for the lubrication and maintenance of gears and tracks. It can avoid both over-maintenance and under-maintenance, and also eliminate the trouble of manual periodic inspections, meeting the production needs of modern enterprises. Attached Figure Description

[0018] Figure 1 This is the control wiring diagram for a bridge crane; Figure 2 This is a schematic diagram of the detection and statistics circuit for the bridge crane of this utility model. Figure 3 This is a circuit diagram of the detection and statistics circuit for the bridge crane of this utility model; Figure 4 This is a circuit diagram of the controller of this utility model; Figure 5 This is a circuit diagram of the controlled power supply unit of this utility model; Figure 6 This is a circuit diagram of the controlled switch relay unit of this utility model. Detailed Implementation

[0019] To make the contents of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0020] Most bridge cranes use remote control for direction. Depending on the lifting weight, the contactors controlling the motor operation are generally available in 36V, 110V, 220V, and 380V types, but the control wiring principle is the same. Figure 1 The diagram shown is a specific wiring diagram for 36V.

[0021] In actual use, the user remotely controls the AC contactor coils in six directions (up, down, east, west, south, and north) by operating the six directional buttons. Once a contactor coil in a certain direction is energized, the contactor immediately engages the 380V main power supply, thereby driving the motor in the corresponding direction to achieve lifting up and down, and movement in all directions (e.g., east, west, north, and south). Figure 1As shown, there are three motors: a vertical lifting motor, an east-west traveling motor, and a north-south traveling motor. Two contactors control the main power supply of the vertical lifting motor, two contactors control the main power supply of the east-west traveling motor, and two contactors control the main power supply of the north-south traveling motor. The motor operates for the duration the button is pressed; it stops immediately upon release of the button, with a control delay typically less than 100ms.

[0022] like Figures 2 to 6 As shown, a detection and statistical circuit for a bridge crane includes intermediate relays K1~K6, a controller, and optocoupler isolation units corresponding to each intermediate relay; wherein, Each intermediate relay has its coil connected to the power supply circuit of the corresponding contactor coil so as to be energized synchronously with the coil of the corresponding contactor, and its switch is connected to the corresponding optocoupler isolation unit. Each optocoupler isolation unit is connected to one input terminal of the controller. The intermediate relay is configured to, when its coil is energized, switch to trigger the corresponding optocoupler isolation unit to count the operating time of the controller.

[0023] Specifically, since most cranes operate using AC trigger switches, and the coils are powered by AC, absolute isolation is essential for signal acquisition. This embodiment employs intermediate relays of the same voltage specification to achieve signal isolation and conversion. Such relays are widely used in industrial control, offering high cost-effectiveness and reliability. Furthermore, given the numerous contactor coil specifications, preferably, the main board only has a soldered base, allowing for easy insertion and removal of intermediate relays to change specifications, cleverly achieving multi-purpose functionality and strong adaptability.

[0024] This embodiment takes into account that the crane is used in a high-voltage, high-electricity environment. In addition to the isolation switch signal of the intermediate relays K1~K6, it is also isolated again by optocouplers. The high voltage that may be generated when the reverse isolation relay is quickly energized is prevented from damaging the low-voltage, low-electricity system.

[0025] The circuit diagram of the detection and statistics circuit for bridge cranes is as follows: Figure 3 As shown, the coil of each intermediate relay is connected in parallel with the coil of the corresponding contactor (one end of the coil of intermediate relays K1-K6 is connected to the live power supply wire of the corresponding contactor coil through pins 3-8 of terminal J2, and the other end of the coil of intermediate relays K1-K6 is connected to the common neutral wire of all contactor coils through pin 10 of terminal J2). One contact of its normally closed switch is grounded, and the other contact is connected to the positive terminal of the power supply and one end of the transmitter of the optocoupler isolation unit, respectively. The other end of the transmitter of the optocoupler isolation unit is grounded; and the power supply of the optocoupler transmitter can also use 100V withstand voltage diodes D3-D8. One end of the receiving end of the optocoupler isolation unit is connected to one input terminal of the controller and is also connected to the positive terminal of the power supply through a resistor, while the other end is grounded.

[0026] In this embodiment, as Figure 2 As shown, preferably, the entire circuit may further include several limit switches, a weight sensor, and a motor encoder, each connected to the controller via a 485 interface. The limit switches are used to detect whether the bridge crane has reached its limit position in the east, west, north, or south directions; the weight sensor is used to detect the lifting weight of the bridge crane. The motor encoder is used to detect the corresponding motor rotation angle and number of revolutions, thereby obtaining the actual height of the bridge crane's hook.

[0027] In this embodiment, as Figure 2 As shown, preferably, the entire circuit may also include a Hall current sensor connected to the 380V input of the vehicle bus, which can detect the motor operating current.

[0028] In this embodiment, as Figure 3 As shown, preferably, the entire circuit may further include indicator units corresponding to each contactor, used to provide indication when the corresponding contactor controls the bridge crane to travel in the corresponding direction. The indicator unit includes a light-emitting diode (LED). Figure 3 (LED3-LED8 in the diagram) The anode of the light-emitting diode is connected to the positive terminal of the power supply through a resistor, and the cathode is connected to one end of the receiving end of the corresponding optocoupler isolation unit of the contactor.

[0029] In this embodiment, as Figure 2 As shown, preferably, the entire circuit also includes a 4G module, a Bluetooth module, etc. The Bluetooth module wirelessly interacts with other external modules, the 4G module is responsible for uploading server data in real time and receiving alarm commands, and the server backend is responsible for recording statistics and displaying numerical or graphical results on the mobile client.

[0030] by Figure 3 Taking a specific circuit as an example, the entire circuit works as follows: When the crane remote control does not press any direction button, the intermediate relays K1~K6 are in the default position. Since pins 4 and 12 of the intermediate relays K1~K6 are closed, pin 1 of all optocouplers is grounded and in a non-conductive state. Pins 3 and 4 of the optocouplers are not conductive. At this time, pins U1-8, U1-9, U1-10, U1-11, U1-24, and U1-25 of the CPU are all at a high level of 3.3V, and all LED indicators are also in a non-grounded and non-lit state.

[0031] When the up button is pressed, the intermediate relay K1 is immediately activated. When pins 12 and 4 of K1 are released, pins 12 and 8 are closed, pin 1 of optocoupler U5 is activated, thus pins 3 and 4 are activated, LED3 is lit, U1-8 are pulled low, the CPU senses the low level change and starts timing after a 100ms delay until the up button is released, and the total time is counted with an accuracy of 100ms.

[0032] When you press and hold the down key, east key, west key, south key, or north key, the principle is the same as when you press and hold the up key.

[0033] The circuit in this embodiment can achieve independent operation in six directions, or simultaneously detect presses in 2-3 directions. The CPU will collect the data and send it to the server for parsing in 6 x 0000 = 24-bit data length. A 100ms delay is included for each press to prevent accidental presses. The server software will record the status every second in real time, regardless of whether data is received, and finally display the crane usage statistics for the year / month / day on a computer or mobile phone interface for the customer.

[0034] In addition, this embodiment can also display the actual stopping position of the crane by calculating the time difference between up and down, east and west, and north and south. It can help enterprises establish a window animation display platform and can also be integrated into the intelligent crane management platform.

[0035] In this embodiment, as Figure 4 As shown, the controller in this embodiment can be the mature 64-pin STM32F103RCT6 from STMicroelectronics, based on the ARM Cortex-M3 core, with a main frequency of 72MHz, equipped with 256KB FLASH program memory and 48KB RAM. It is fast, reliable, inexpensive, has many available I / Os, and rich external communication interfaces, and is widely used in IoT devices, intelligent control systems and industrial fields.

[0036] In addition, due to the complex environment and numerous interferences at the crane site, a software watchdog function has been added to prevent the controller from crashing unexpectedly due to interference. When the controller does not continuously send a specific frequency signal to the watchdog chip, a timeout mechanism will be triggered after 60 seconds. The watchdog chip's WDO will be briefly pulled low for 1 second, enabling the microcontroller (controller) to be reset once, thereby restarting the main program.

[0037] In this embodiment, as Figure 5 As shown, the entire circuit may also include a controlled power supply unit, including transistor Q2, MOSFET Q1, and power output port J11; wherein, The base of transistor Q2 is connected to the controller, the collector is connected to a positive power supply (+12V) through resistor R35, and is also connected to the gate of MOSFET Q1 through resistor R36. The emitter is grounded. The source of MOSFET Q1 is connected to the positive terminal of the power supply (+12V), the drain is connected to terminal 1 of the power output port, and terminal 2 of the power output port is grounded.

[0038] Specifically, through the controlled power supply unit, it can support some 12V DC alarm lights, forming a complete ecosystem of data acquisition, processing, and alarm functions, helping users solve unknown safety problems and greatly improving production efficiency.

[0039] Additionally, terminal 3 of the power output port can be connected to a positive power supply (+12V), which is generally used to power some sensors, such as room temperature sensors. However, this is not needed in most scenarios and can be left unused.

[0040] In this embodiment, as Figure 6 As shown, the entire circuit may also include a controlled switch relay unit, comprising transistor Q4 and relay K7; wherein, The base of transistor Q4 is connected to the controller, and the collector is connected to one end of the coil of relay K7. The transmitter is grounded. The other end of the coil of relay K7 is connected to a positive power supply.

[0041] Controlled switch relay units are generally used to help customers turn off some devices, such as camera systems, because in order to save power consumption, some customers need to turn off unused devices at night, or leave them unused.

[0042] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A detection and statistical circuit for a bridge crane, the bridge crane comprising upper, lower, east, west, south, and north contactors respectively controlling the upper, lower, east, west, south, and north travel; characterized in that, The bridge crane detection and statistics circuit includes intermediate relays K1~K6, a controller, and optocoupler isolation units corresponding to each intermediate relay; among which, Each intermediate relay has its coil connected to the power supply circuit of the corresponding contactor coil so as to be energized synchronously with the coil of the corresponding contactor, and its switch is connected to the corresponding optocoupler isolation unit. Each optocoupler isolation unit is connected to one input terminal of the controller. The intermediate relay is configured to, when its coil is energized, switch to trigger the corresponding optocoupler isolation unit to count the operating time of the controller.

2. The bridge crane detection and statistical circuit according to claim 1, characterized in that, It also includes several limit switches connected to the controller, used to detect whether the bridge crane has reached its limit position in the east, west, north, and south directions.

3. The bridge crane detection and statistical circuit according to claim 1, characterized in that, It also includes a weight sensor connected to the controller for detecting the lifting weight of the bridge crane.

4. The bridge crane detection and statistical circuit according to claim 1, characterized in that, It also includes a motor encoder, connected to the controller, for detecting the actual height of the hook of the bridge crane.

5. The bridge crane detection and statistical circuit according to claim 1, characterized in that, Each intermediate relay has its coil connected in parallel with the corresponding contactor coil. One contact of its normally closed switch is grounded, and the other contact is connected to the positive terminal of the power supply and one end of the transmitter of the optocoupler isolation unit, respectively. The other end of the transmitter of the optocoupler isolation unit is grounded. One end of the receiving end of the optocoupler isolation unit is connected to one input terminal of the controller and is also connected to the positive terminal of the power supply through a resistor, while the other end is grounded.

6. The bridge crane detection and statistical circuit according to claim 1, characterized in that, It also includes an indicator unit corresponding to each of the contactors, used to give an indication when the corresponding contactor controls the bridge crane to travel in the corresponding direction.

7. The bridge crane detection and statistical circuit according to claim 6, characterized in that, The indicator unit includes a light-emitting diode (LED). The anode of the LED is connected to the positive terminal of the power supply via a resistor, and the cathode is connected to one end of the receiving end of the corresponding optocoupler isolation unit of the contactor.

8. The bridge crane detection and statistical circuit according to claim 1, characterized in that, It also includes a controlled power supply unit, comprising transistor Q2, MOSFET Q1, and power output port J11; wherein, The base of transistor Q2 is connected to the controller, the collector is connected to a positive power supply through resistor R35, and is also connected to the gate of MOSFET Q1 through resistor R36. The emitter is grounded. The source of MOSFET Q1 is connected to the positive terminal of the power supply, the drain is connected to terminal 1 of the power output port, and terminal 2 of the power output port is grounded.

9. The bridge crane detection and statistical circuit according to claim 8, characterized in that, Terminal 3 of the power output port is connected to a positive power supply.

10. The bridge crane detection and statistical circuit according to claim 1, characterized in that, It also includes a controlled switch relay unit, comprising transistor Q4 and relay K7; wherein, The base of transistor Q4 is connected to the controller, the collector is connected to one end of the coil of relay K7, and the emitter is grounded; the other end of the coil of relay K7 is connected to a positive power supply.

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