A crown block remote monitoring and control system

Abstract

The utility model provides a kind of crown block remote monitoring control system, it is related to crown block technical field.The crown block remote monitoring control system of the utility model, including crown block control system and bridge equipment, the crown block control system is connected with the bridge equipment, the bridge equipment is connected with ground terminal equipment communication;The crown block control system is used to gather the operation data of different crown block components, and is transmitted to the ground terminal equipment by the bridge equipment, and the ground terminal equipment real-time shows the operation state and fault information of the crown block component.The utility model avoids the error and lag caused by previous manual reading or single instrument monitoring, and fundamentally eliminates the complexity and delay caused by the dependence of traditional crown block communication system on multi-level transfer and redundant routing, and greatly improves safety and work efficiency.

Description

Technical Field

[0001] This utility model relates to the field of overhead crane technology, and more specifically, to an overhead crane remote monitoring and control system. Background Technology

[0002] As one of the core pieces of equipment in electrolytic aluminum production, the multi-functional overhead crane unit is mainly used to complete a variety of key operations in the electrolytic cell production process, including anode replacement, shell breaking, adding electrolyte insulation material, adding aluminum fluoride powder, grab bucket slag removal, aluminum tapping, busbar lifting, and material hoisting. Therefore, the operating status and control precision of the overhead crane unit directly affect the safety, stability, and economy of electrolytic aluminum production.

[0003] In related technologies, when the crane unit malfunctions, technicians need to personally climb the crane and connect to the PLC system (Programmable Logic Controller) via wired connection to perform program testing and signal troubleshooting. This is not only cumbersome and time-consuming, but also poses certain safety risks. Utility Model Content

[0004] The problem this invention addresses is how to quickly and effectively troubleshoot overhead crane unit malfunctions.

[0005] To address the aforementioned problems, this utility model provides a remote monitoring and control system for overhead cranes, comprising an overhead crane control system and a network bridge device. The overhead crane control system is connected to the network bridge device, and the network bridge device is communicatively connected to a ground terminal device. The overhead crane control system is used to collect operating data of different overhead crane components and transmit it to the ground terminal device through the network bridge device. The ground terminal device displays the operating status and fault information of the overhead crane components in real time.

[0006] Optionally, the operating data includes status data and parameter data. The status data includes at least one of the following: the cylinder lifting and lowering position signal of the crane assembly, the start or stop signal of the actuator motor, the fault alarm signal, and the operating status signal of the auxiliary equipment. The parameter data includes at least one of the following: the control voltage of the pressure valve and flow valve of the crane assembly, the motor operating current, and the motor operating time parameter.

[0007] Optionally, the crane control system is configured to acquire the operating data from a detection element of the crane assembly, the detection element including at least one of a limit switch, a current sensor, and a pressure sensor.

[0008] Optionally, the overhead crane control system is configured to connect to the bridge device via a communication interface, which includes a bus port or an Ethernet interface.

[0009] Optionally, when the communication interface is a bus port, the bridge device is configured to perform protocol conversion on the operating data and then transmit it to the ground terminal device; when the communication interface is an Ethernet interface, the bridge device is configured to directly transmit the operating data to the ground terminal device.

[0010] Optionally, the bridge device is installed above the side of the overhead crane and is equipped with a directional antenna whose main radiation direction is towards the ground; multiple wireless access points are set on the ground along the direction of the overhead crane's running track, and each wireless access point is equipped with a sector antenna. The coverage area of ​​the sector antenna corresponds to different sections of the overhead crane's running track. The directional antenna and the sector antennas of each wireless access point form a continuous line-of-sight wireless communication path within the overhead crane's running range. The bridge device is configured to establish a communication connection with the ground terminal device through the wireless access points.

[0011] Optionally, the overhead crane control system is connected to the bridge device via a switch. The switch is installed in the power distribution cabinet on the overhead crane beam, and the switch and the bridge device are connected via shielded twisted-pair cable or industrial fiber optic communication cable.

[0012] Optionally, the overhead crane assembly includes an actuator and a power system, the power system being used to provide driving force to the actuator, the actuator including at least one of a shell-breaking mechanism, a pole-changing mechanism, a material feeding mechanism, and a slag-removing mechanism, and the power system including a pneumatic system and / or a hydraulic system.

[0013] Optionally, the pneumatic system includes an air compressor, an air tank, a pressure reducing valve, a filter, a solenoid directional valve, and a cylinder. The air compressor is connected to the air tank via an external air source interface. The output end of the air tank is connected to the solenoid directional valve via the pressure reducing valve and the filter. The solenoid directional valve is connected to the cylinder of the actuator via the cylinder.

[0014] Optionally, the hydraulic system includes a hydraulic oil tank, a hydraulic pump, a solenoid directional valve, a throttle valve, and hydraulic cylinders. The oil inlet of the hydraulic pump is connected to the hydraulic oil tank, and the oil outlet of the hydraulic pump is connected to the oil inlet of each hydraulic cylinder via the solenoid directional valve and the throttle valve. The piston of the hydraulic cylinder is connected to the mechanical transmission unit of the actuator.

[0015] The beneficial effects of this utility model's remote monitoring and control system for overhead cranes are as follows: By configuring an independent overhead crane control system at the crane body, centralized data collection and preprocessing can be achieved at the source, providing an accurate source of basic data for remote monitoring and avoiding the errors and lags caused by manual reading or single instrument monitoring in the past; the network bridge device plays the role of bridging communication protocols and establishing network channels, enabling the data of the overhead crane control system to be transmitted seamlessly and with low latency to the ground terminal equipment, fundamentally eliminating the complexity and delay caused by the reliance on multi-level relays and redundant routing in traditional overhead crane communication systems; by setting up terminal equipment on the ground, maintenance personnel can perform real-time monitoring and management of the overhead crane system in a safe environment, reducing the frequency of high-altitude operations and on-site inspections, and significantly improving safety and work efficiency. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the overhead crane remote monitoring and control system according to an embodiment of the present utility model; Figure 2 This is a schematic diagram of the principle of the overhead crane remote monitoring and control system according to an embodiment of the present invention. Figure 1 ; Figure 3 This is a schematic diagram of the principle of the overhead crane remote monitoring and control system according to an embodiment of the present invention. Figure 2 . Detailed Implementation

[0017] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Although some embodiments of this utility model are shown in the drawings, it should be understood that this utility model can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this utility model. It should be understood that the drawings and embodiments of this utility model are for illustrative purposes only and are not intended to limit the scope of protection of this utility model.

[0018] It should be understood that the steps described in the method embodiments of this utility model may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of this utility model is not limited in this respect.

[0019] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this utility model are only used to distinguish different devices, modules, or units, and are not used to limit the order of functions performed by these devices, modules, or units or their interdependencies.

[0020] It should be noted that the terms "one" and "multiple" used in this utility model are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0021] The names of the messages or information exchanged between the multiple devices in this embodiment of the invention are for illustrative purposes only and are not intended to limit the scope of these messages or information.

[0022] like Figure 1 As shown in the figure, an embodiment of the present invention provides a remote monitoring and control system for overhead cranes, including an overhead crane control system and a network bridge device. The overhead crane control system is connected to the network bridge device, and the network bridge device is communicatively connected to a ground terminal device. The overhead crane control system is used to collect operating data of different overhead crane components and transmit it to the ground terminal device through the network bridge device. The ground terminal device displays the operating status and fault information of the overhead crane components in real time.

[0023] Specifically, in combination Figure 2 and Figure 3As shown, the overhead crane remote monitoring and control system includes an overhead crane control system (e.g., a PLC workstation) and a network bridge device. The overhead crane control system can be installed on the main body of the overhead crane to collect operating data from each crane component. A network communication line is connected to the network bridge device via a switch in the overhead crane's power distribution cabinet, thus connecting the overhead crane control system and the network bridge device. The network bridge device establishes a communication connection with the ground terminal device when they are on the same network segment (the first few bits of their IP addresses are the same, and they use the same subnet mask, such as 255.255.255.0). For example, the network bridge device can communicate with the ground terminal device through a main radiating direction. A line-of-sight wireless communication path is established between the directional antenna pointing to the ground and the sector antennas set along the crane's running track, and the ground terminal equipment. This allows the operational data collected by the crane control system to be transmitted to the ground terminal equipment (e.g., a mobile terminal, which can be located on the workshop floor or in the control room). The ground terminal equipment displays the operating status and fault information of the crane components in real time. Technicians can quickly analyze the cause of the fault based on the operating status and fault information, formulate maintenance plans, significantly shorten the troubleshooting and maintenance time, reduce crane downtime, reduce the impact on production, and ensure the smooth operation of the electrolytic aluminum production process.

[0024] An exemplary monitoring and control process is as follows: Maintenance personnel log in to the management interface of the ground terminal device and enter the wizard page. They set the device name, IP address (address and subnet mask: ensure the address does not conflict with other devices on the network), and the wireless network name, encryption method, and password of the bridge device. After completing the settings, the ground terminal device can search for the WIFI with the wireless name set by the bridge device. After connecting, the ground terminal device can access the crane control system monitoring screen in real time. For example, by opening the PLC software on the ground terminal device, selecting the sub-file in the taskbar, and opening the corresponding subroutine, all operating conditions can be viewed, allowing for the quickest identification of electrical faults. Information such as network faults of the frequency converter and other switches, whether the PLC program is missing, the structure of the PLC program can be edited, and the operating parameters of each mechanism of the hydraulic station can be remotely edited.

[0025] The overhead crane control system can use the RSLogix5000 program system.

[0026] The ground terminal equipment can be a laptop, industrial tablet, or host computer. After the ground terminal equipment completes network parameter matching, it enters the same IP network segment as the bridge equipment. The network interface module of the ground terminal equipment establishes a communication connection with the bridge equipment through wired network cable or wireless WiFi, thereby directly accessing the overhead crane control system.

[0027] The ground terminal equipment is equipped with an editing module. Based on a communication protocol compatible with the overhead crane control system, the editing module can directly call the PLC control program in the terminal interface. When the PLC control logic or operating parameters need to be modified, the operator can modify the logic, adjust the parameters, or update the program on the ground terminal equipment. After editing, the modified program can be rewritten into the PLC through the network bridge equipment, realizing remote reverse programming and system maintenance. The modification and download of the PLC control program can be completed without climbing the overhead crane, which greatly improves the safety and efficiency of operation and maintenance.

[0028] The ground terminal equipment includes an adjustment module for remotely adjusting the operating parameters of the hydraulic station and various actuators. Adjustable parameters include pressure valve opening, flow valve set voltage, motor operating current, actuator cylinder action time, and lifting speed. The ground terminal equipment transmits adjustment commands to the overhead crane control system via a network bridge. The overhead crane control system updates the control output parameters in real time, enabling remote control and optimization of the parameters of the overhead crane actuators under different production conditions, thus improving the system's flexibility and intelligence.

[0029] The ground terminal equipment is equipped with data monitoring software (such as configuration software or self-developed application) to receive and parse the operating data forwarded by the bridge equipment. The software interface displays the operating status, execution parameters and alarm information of each crane component in real time. When a network abnormality is detected in the frequency converter or switch, the ground terminal equipment automatically displays a network fault prompt on the interface, which is convenient for maintenance personnel to diagnose in a timely manner.

[0030] In this embodiment, by configuring an independent crane control system at the crane body, centralized data collection and preprocessing can be achieved at the source, providing an accurate source of basic data for remote monitoring and avoiding the errors and delays caused by manual reading or single instrument monitoring in the past. The network bridge device plays the role of bridging communication protocols and establishing network channels, enabling the data of the crane control system to be transmitted seamlessly and with low latency to the ground terminal equipment, fundamentally eliminating the complexity and delay caused by the reliance on multi-level relays and redundant routing in traditional crane communication systems. By setting up terminal equipment on the ground, maintenance personnel can monitor and manage the crane system in real time in a safe environment, reducing the frequency of high-altitude operations and on-site inspections, and significantly improving safety and work efficiency.

[0031] Optionally, the operating data includes status data and parameter data. The status data includes at least one of the following: the cylinder lifting and lowering position signal of the crane assembly, the start or stop signal of the actuator motor, the fault alarm signal, and the operating status signal of the auxiliary equipment. The parameter data includes at least one of the following: the control voltage of the pressure valve and flow valve of the crane assembly, the motor operating current, and the motor operating time parameter.

[0032] Specifically, the overhead crane control system is configured to collect operational data from different overhead crane components. This operational data includes status data and parameter data. Status data includes signals indicating the lifting and lowering positions of the crane components' cylinders, the start or stop of the actuator motors, fault alarm signals, and auxiliary equipment operating status signals. Parameter data includes the control voltage of the pressure valves and flow valves of the crane components, the motor operating current, and the motor operating time parameters. Taking the shell-breaking mechanism as an example, status data includes signals indicating the lifting and lowering positions of the shell-breaking mechanism's cylinders and the extension and retraction positions of the shell-breaking machine's tilting cylinders (limit switches), the motor's start / stop status (contactor auxiliary contacts), fault alarm signals (overload protection switches), and the radiator's start / stop status. Parameter data includes parameters of the shell-breaking lifting mechanism (pressure valve low-speed rise voltage DC3V, flow valve low-speed rise voltage DC3V; pressure valve high-speed rise voltage DC6V, flow valve high-speed rise voltage DC4V; pressure valve low-speed descent voltage DC3V, flow valve low-speed descent voltage DC3V; pressure valve high-speed descent voltage DC7.5V, flow valve high-speed descent voltage DC3.5V), motor operating current (current sensor), and motor operation detection (timer).

[0033] In this optional embodiment, by dividing the crane operation data into status data and parameter data, the system can collect and analyze the equipment's action status (such as limit switches, start / stop, and alarms) and operating parameters (such as pressure, current, and time) in layers, which facilitates status judgment, trend analysis, and fault diagnosis on ground terminal equipment, thereby improving the system's monitoring accuracy and intelligence level.

[0034] Optionally, the crane control system is configured to acquire the operating data from a detection element of the crane assembly, the detection element including at least one of a limit switch, a current sensor, and a pressure sensor.

[0035] Specifically, through the limit switches, current sensors, pressure sensors, flow sensors and other detection elements on the crane assembly, mechanical actions or physical quantities can be converted into electrical signals, such as 24V DC switching quantities, 4-20mA analog quantities or pulse signals. The crane control system receives the above electrical signals and converts them into recognizable digital signals, performs calculations on the data (such as determining whether the hydraulic cylinder is in position), and temporarily stores the original data and processing results in the PLC internal register.

[0036] In this optional embodiment, mechanical motion or physical quantity signals are converted into electrical signals by detection elements such as limit switches, current sensors, and pressure sensors, enabling the system to obtain the operating information of each actuator and power system in real time and accurately, providing a reliable data foundation for subsequent communication and control.

[0037] Optionally, the overhead crane control system is configured to connect to the bridge device via a communication interface, which includes a bus port or an Ethernet interface.

[0038] Specifically, the overhead crane control system is connected to the bridge device through a communication interface. The communication interface can be a bus port (such as an RS485 port) or an Ethernet interface. When using an RS485 port, the overhead crane control system and the bridge device can communicate using the Modbus RTU protocol. When using an Ethernet interface, the overhead crane control system and the bridge device can communicate using the Modbus TCP / IP protocol.

[0039] In this optional embodiment, by configuring both bus ports and Ethernet interfaces in the crane control system, the system can be flexibly adapted to different PLC models and workshop network environments, enhancing the system's versatility and scalability, and avoiding communication limitations caused by interface incompatibility.

[0040] Optionally, when the communication interface is a bus port, the bridge device is configured to perform protocol conversion on the operating data and then transmit it to the ground terminal device; when the communication interface is an Ethernet interface, the bridge device is configured to directly transmit the operating data to the ground terminal device.

[0041] Specifically, when the trolley control system uses RS485 communication, the bridge device performs protocol conversion on the received Modbus RTU protocol data, converting it into Modbus TCP / IP data in Ethernet format before sending it to the ground terminal equipment. When the trolley control system uses Ethernet communication, the bridge device directly transmits the data without protocol conversion.

[0042] In this optional embodiment, the bridge device can automatically perform protocol conversion or data pass-through according to the communication interface type, realize seamless data interaction between different protocols, significantly improve the flexibility and compatibility of data transmission, simplify the communication architecture, and at the same time ensure the real-time performance and reliability of data transmission.

[0043] Optionally, the bridge device is installed above the side of the overhead crane and is equipped with a directional antenna whose main radiation direction is towards the ground; multiple wireless access points are set on the ground along the direction of the overhead crane's running track, and each wireless access point is equipped with a sector antenna. The coverage area of ​​the sector antenna corresponds to different sections of the overhead crane's running track. The directional antenna and the sector antennas of each wireless access point form a continuous line-of-sight wireless communication path within the overhead crane's running range. The bridge device is configured to establish a communication connection with the ground terminal device through the wireless access points.

[0044] Specifically, the bridge equipment is fixedly installed on a bracket near the top of the overhead crane, away from motors, frequency converters, etc. The bridge equipment is equipped with a high-gain directional antenna, whose main radiation direction is towards the ground below, to form a stable line-of-sight transmission path with the ground access point. The antenna housing adopts a metal shielding and dustproof / heat-insulating structure to adapt to the high-temperature, high-dust environment of the electrolytic aluminum workshop. Multiple wireless access points (APs) are set along the crane's running track. Each access point is equipped with a sector antenna, whose radiation sector covers a specific section of the track. The coverage sections of adjacent APs overlap to ensure a smooth signal transition during crane movement and avoid communication interruptions due to area switching. APs can be set on pillars on the workshop walls to ensure unobstructed access between the APs and the bridge equipment. A continuous line-of-sight wireless communication link is formed between the directional antenna on the crane side and the ground AP sector antenna throughout the entire operating range. When the crane moves to different sections, the bridge equipment automatically connects to the AP with the strongest signal, reducing electromagnetic interference through adaptive power control and channel frequency hopping technology.

[0045] Among them, the electrolytic aluminum production workshop has the following electromagnetic and physical environment characteristics: (1) The working current of the electrolytic cell is as high as hundreds of thousands of amperes, generating strong magnetic fields and harmonic interference; (2) The overhead crane crosses multiple electrolytic cell areas, and there are a large number of high-power conductors and busbars around it; (3) The workshop has high temperature, high dust concentration, and dense metal structure, which makes wireless signals easy to reflect, attenuate and multipath interference; (4) The wireless communication points arranged on the top or in the center of the workshop often have signal blind spots, communication delays or data packet loss. These factors make the traditional overhead crane wireless communication system less stable in the electrolytic aluminum workshop. PLC data and control commands may experience momentary interruptions or delays, affecting the safety and accuracy of the overhead crane operation. In this embodiment, the network bridge device is fixed on the support above the side of the overhead crane, positioned higher than the edge of the electrolytic cell, and arranged opposite to the wireless access point (AP) on one side of the workshop floor. The installation height and angle between the two are calculated and adjusted to form an unobstructed line-of-sight transmission path throughout the entire travel of the overhead crane. This effectively improves the communication stability and real-time performance of the overhead crane remote monitoring and control system, and also enhances the system's noise resistance and safety performance in a highly interfering industrial environment, ensuring the continuity and reliability of the electrolytic aluminum production process.

[0046] The bridge device is equipped with a real-time signal quality monitoring module, which continuously monitors the signal quality parameters between the directional antenna on the crane side and multiple ground wireless access points as the crane moves along the operating track. These parameters include at least one of the following: received signal strength indication, signal-to-noise ratio, link quality indication, bit error rate, and packet loss rate. To ensure the continuity of the wireless link, when any signal quality parameter of the currently connected wireless access point falls below a preset threshold, the bridge device triggers a pre-scanning process to quickly probe the adjacent wireless access points near the current position of the crane. During the probe, the bridge device acquires the real-time signal quality parameters of each adjacent wireless access point at the current moment and uses this as a basis to prioritize the adjacent wireless access points. After prioritization, the bridge device selects the wireless access point with the best signal quality as a candidate switching target. When it detects that the current link is about to become unstable, it immediately performs a wireless link switching operation, enabling seamless roaming of the crane between different coverage areas. This effectively reduces connection interruptions caused by wireless link attenuation or obstruction during crane operation and improves the reliability of system data transmission.

[0047] The multiple wireless access points along the overhead crane track are installed in a segmented layout. Each pair of adjacent access points is equipped with sector antennas with different coverage areas. To ensure stable line-of-sight communication for the crane in different operating sections, the coverage areas of each sector antenna are designed to have partial overlap between adjacent sections. The overlapping area accounts for 10% to 30% of the horizontal coverage angle of the corresponding sector antenna. This allows the crane to receive signals from the next segment's wireless access point even when approaching the end of a section, ensuring comparable link quality and smooth transition during wireless access point switching on the crane-side network bridge. Furthermore, by reasonably adjusting the horizontal angle and downtilt angle of the sector antennas, a continuous, low-loss line-of-sight communication path is formed between coverage sections. This avoids signal blind spots caused by buildings or equipment obstructing the crane's track at both ends or in the middle, effectively improving the continuity and anti-interference capability of wireless coverage within the large-span electrolysis workshop and ensuring the stability of data monitoring and control command transmission.

[0048] In this optional embodiment, the layout scheme of forming a line-of-sight path between the crane-side network bridge and the ground AP not only effectively improves the communication stability and real-time performance of the crane remote monitoring and control system, but also enhances the system's noise resistance and safety performance in a highly interfering industrial environment, ensuring the continuity and reliability of the electrolytic aluminum production process.

[0049] Optionally, the overhead crane control system is connected to the bridge device via a switch. The switch is installed in the power distribution cabinet on the overhead crane beam, and the switch and the bridge device are connected via shielded twisted-pair cable or industrial fiber optic communication cable.

[0050] Specifically, the overhead crane control system can be connected to the bridge device via an industrial switch installed in the overhead crane beam power distribution cabinet. The bridge device can be fixedly installed on the top of the overhead crane near an area with unobstructed signal coverage to shorten the communication line length and improve the stability of wireless signal transmission. The switch and the bridge device are connected via shielded twisted-pair cable or industrial fiber optic communication cable, which can effectively reduce the interference of strong electromagnetic fields and high-temperature dust environment in the electrolytic cell workshop on communication.

[0051] In this optional embodiment, by using shielded cables to connect the switch and the bridge device, the interference of strong electromagnetic fields and high-temperature dust environment in the electrolytic cell workshop on communication can be effectively reduced, thereby improving the long-term operational reliability of the system.

[0052] Optionally, the overhead crane assembly includes an actuator and a power system, the power system being used to provide driving force to the actuator, the actuator including at least one of a shell-breaking mechanism, a pole-changing mechanism, a material feeding mechanism, and a slag-removing mechanism, and the power system including a pneumatic system and / or a hydraulic system.

[0053] Specifically, in combination Figure 2 and Figure 3 As shown, the overhead crane assembly includes an actuator and a power system. The actuator includes a shell-breaking mechanism, an electrode-changing mechanism, a feeding mechanism, and a slag-removing mechanism. The shell-breaking mechanism is mainly used to break the electrolyte crust on the surface of the electrolytic cell to facilitate operations such as anode replacement and alumina addition. Its core function is to break the hard electrolyte crust through mechanical impact, thereby exposing the internal structure of the electrolytic cell and facilitating subsequent processes. The electrode-changing mechanism is mainly used to clamp the guide rod of the consumed anode carbon block, clamping and removing the consumed anode carbon block from the electrolytic cell, and then clamping a new anode carbon block and placing it in the electrolytic cell position. This is mainly for replacing the anode carbon blocks in the electrolytic cell. During the electrolytic aluminum production process, the electrolytic cell produces a large amount of carbon slag. If not... Timely cleaning can lead to decreased current efficiency, increased energy consumption, and potential corrosion of the electrolytic cell lining. The slag removal mechanism uses mechanical devices to remove carbon slag from the electrolytic cell, reducing dead corner residue and ensuring production safety and efficiency. The feeding mechanism is mainly used to add raw materials such as electrolytes and alumina into the electrolytic cell. It is mainly done by extending the feed pipe into the required feeding position and feeding downwards. The power system includes a pneumatic system and a hydraulic system, which provide power for the operation of the above mechanisms. The overhead crane control system is electrically connected to the above actuators and the power system, respectively, to collect operating signals in real time and perform logic control. The ground terminal equipment can display the operating status curves, alarm information, and parameter changes of each mechanism in real time, realizing centralized remote monitoring.

[0054] In this optional embodiment, by dividing the overhead crane components into actuators and a power system, a clear system structure hierarchy is established. The actuators are responsible for specific operational actions, while the power system provides driving force. This facilitates unified data acquisition and control by the overhead crane control system, enabling coordinated operation and centralized monitoring of all crane mechanisms, thereby improving the overall operating efficiency and safety performance of the crane.

[0055] Optionally, the pneumatic system includes an air compressor, an air tank, a pressure reducing valve, a filter, a solenoid directional valve, and a cylinder. The air compressor is connected to the air tank via an external air source interface. The output end of the air tank is connected to the solenoid directional valve via the pressure reducing valve and the filter. The solenoid directional valve is connected to the cylinder of the actuator via the cylinder.

[0056] Specifically, the pneumatic system includes an air compressor, an air tank, a pressure reducing valve, a filter, a solenoid directional valve, and cylinders. The air compressor is connected to the air tank via an external air source interface to provide stable compressed air. The output end of the air tank is connected to the solenoid directional valve after passing through the pressure reducing valve and the filter. The pressure reducing valve is used to adjust the output air pressure to the required working range, while the filter is used to remove impurities and moisture from the gas to ensure system cleanliness and valve life. The output end of the solenoid directional valve is connected to the cylinders of the actuators (such as the feeding mechanism and the slag removal mechanism) via air pipes. When the trolley control system outputs a control signal, the solenoid directional valve switches the path direction, causing the cylinder to extend and retract, thereby driving the actuator. For example, the cylinder of the feeding mechanism pushes the material pipe into the top of the electrolytic cell for feeding, and the cylinder of the slag removal mechanism drives the clamps to open and close, realizing the clamping and release of carbon slag.

[0057] In this optional embodiment, the pneumatic system enables rapid response and high-frequency action, which has significant advantages over traditional single hydraulic drive solutions in terms of action speed, maintenance convenience, and air source sharing.

[0058] Optionally, the hydraulic system includes a hydraulic oil tank, a hydraulic pump, a solenoid directional valve, a throttle valve, and hydraulic cylinders. The oil inlet of the hydraulic pump is connected to the hydraulic oil tank, and the oil outlet of the hydraulic pump is connected to the oil inlet of each hydraulic cylinder via the solenoid directional valve and the throttle valve. The piston of the hydraulic cylinder is connected to the mechanical transmission unit of the actuator.

[0059] Specifically, the hydraulic system includes a hydraulic oil tank, a hydraulic pump, a solenoid directional valve, a throttle valve, and hydraulic cylinders. The hydraulic pump is driven by a motor, draws oil from the hydraulic oil tank, and outputs high-pressure liquid. The high-pressure oil flows into each hydraulic cylinder after being controlled by the solenoid directional valve and the throttle valve. An overflow valve is installed on the main oil line to maintain system pressure stability and prevent overload. The hydraulic pipeline delivers the high-pressure oil to the shell-breaking mechanism, the electrode-changing mechanism, and the slag-removing mechanism. The piston rod of the hydraulic cylinder is connected to the mechanical transmission unit of the actuator to realize lifting, clamping, or impact actions. For example, in the shell-breaking mechanism, the hydraulic cylinder drives the shell-breaking hammer to reciprocate up and down to break the electrolyte shell surface. In the electrode-changing mechanism, the hydraulic cylinder drives the clamping arm to open and close and lift to complete the disassembly and assembly of the anode carbon block. In the slag-removing mechanism, the hydraulic cylinder realizes the main lifting action of the slag-removing arm and works in coordination with the pneumatic clamp.

[0060] In this optional embodiment, the hydraulic system can stably output large thrust under high temperature and high load conditions, with smooth and high precision operation, enabling the crane to simultaneously possess high torque output capability and rapid response performance, significantly improving the overall operating efficiency and operational safety.

[0061] Although the present invention has been disclosed above, its protection scope is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the protection scope of the present invention.

Claims

1. A remote monitoring and control system for overhead cranes, characterized in that, It includes a crane control system and a network bridge device. The crane control system is connected to the network bridge device, and the network bridge device is communicatively connected to a ground terminal device. The crane control system is used to collect operating data of different crane components and transmit it to the ground terminal device through the network bridge device. The ground terminal device displays the operating status and fault information of the crane components in real time.

2. The overhead crane remote monitoring and control system according to claim 1, characterized in that, The operational data includes status data and parameter data. The status data includes at least one of the following: the hydraulic cylinder lifting and lowering position signal of the crane assembly, the start or stop signal of the actuator motor, the fault alarm signal, and the operating status signal of the auxiliary equipment. The parameter data includes at least one of the following: the control voltage of the pressure valve and flow valve of the crane assembly, the motor operating current, and the motor operating time parameter.

3. The overhead crane remote monitoring and control system according to claim 2, characterized in that, The crane control system is configured to acquire the operating data from detection elements of the crane assembly, the detection elements including at least one of limit switches, current sensors, and pressure sensors.

4. The overhead crane remote monitoring and control system according to claim 1, characterized in that, The overhead crane control system is configured to connect to the bridge device via a communication interface, which includes a bus port or an Ethernet interface.

5. The overhead crane remote monitoring and control system according to claim 4, characterized in that, When the communication interface is a bus port, the bridge device is configured to perform protocol conversion on the operating data and then transmit it to the ground terminal device; when the communication interface is an Ethernet interface, the bridge device is configured to directly transmit the operating data to the ground terminal device.

6. The overhead crane remote monitoring and control system according to claim 1, characterized in that, The network bridge device is installed above the side of the overhead crane and is equipped with a directional antenna whose main radiation direction is towards the ground. Multiple wireless access points are set on the ground along the direction of the overhead crane's running track. Each wireless access point is equipped with a sector antenna. The coverage area of ​​the sector antenna corresponds to different sections of the overhead crane's running track. The directional antenna and the sector antennas of each wireless access point form a continuous line-of-sight wireless communication path within the overhead crane's running range. The network bridge device is configured to establish a communication connection with the ground terminal device through the wireless access points.

7. The overhead crane remote monitoring and control system according to claim 1, characterized in that, The overhead crane control system is connected to the bridge device via a switch. The switch is installed in the power distribution cabinet on the overhead crane beam, and the switch and the bridge device are connected via shielded twisted-pair cable or industrial fiber optic communication cable.

8. The overhead crane remote monitoring and control system according to any one of claims 1 to 7, characterized in that, The overhead crane assembly includes an actuator and a power system. The power system provides driving force to the actuator, which includes a shell-breaking mechanism, a pole-changing mechanism, a material feeding mechanism, and a slag-removing mechanism. The power system includes a pneumatic system and a hydraulic system.

9. The overhead crane remote monitoring and control system according to claim 8, characterized in that, The pneumatic system includes an air compressor, an air tank, a pressure reducing valve, a filter, a solenoid directional valve, and a cylinder. The air compressor is connected to the air tank through an external air source interface. The output end of the air tank is connected to the solenoid directional valve through the pressure reducing valve and the filter. The solenoid directional valve is connected to the cylinder of the actuator through the cylinder.

10. The overhead crane remote monitoring and control system according to claim 8, characterized in that, The hydraulic system includes a hydraulic oil tank, a hydraulic pump, a solenoid directional valve, a throttle valve, and hydraulic cylinders. The suction port of the hydraulic pump is connected to the hydraulic oil tank, and the outlet port of the hydraulic pump is connected to the inlet port of each hydraulic cylinder via the solenoid directional valve and the throttle valve. The piston of the hydraulic cylinder is connected to the mechanical transmission unit of the actuator.

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