A shore crane trolley positioning automatic checking device

Abstract

The utility model discloses a kind of shore bridge trolley positioning automatic calibration device, it is related to port shore bridge equipment automation modification technical field, comprising: inductive magnet component, magnetic induction limiting component, absolute position encoder component and PLC connecting component;Inductive magnet component includes multiple inductive magnets set on the sea survey track of port berth shore bridge, magnetic induction limiting component includes multiple adjustable supports set on the shore bridge trolley car and the magnetic induction limiting body set at the end of adjustable support, absolute position encoder component includes the absolute position encoder set on the side of driven wheel, the waterproof cover shell set above absolute position encoder and fiber relay device;PLC connecting component includes programmable logic controller and communication interface, and programmable logic controller is connected with absolute position encoder and magnetic induction limiting body by communication interface.The utility model has alleviated the technical problem of insufficient positioning accuracy and error accumulation in the prior art.

Description

Technical Field

[0001] This utility model relates to the field of automated transformation technology of port quay crane equipment, specifically an automatic calibration device for quay crane trolley positioning. Background Technology

[0002] Currently, most automated terminals use BTG's magnetic nail positioning solution to solve the problem of trolley positioning. However, this solution has significant disadvantages: the cost of a single magnetic nail positioning receiver is more than RMB 100,000, and the implementation and maintenance costs of the entire system are high, resulting in poor economic efficiency. At the same time, the solution does not have a dedicated protective structure designed for the complex operating environment of ports, which is humid, dusty, and salty, resulting in a high equipment failure rate and difficulty in long-term stable operation.

[0003] Meanwhile, existing quay crane positioning systems mostly use single-point deviation elimination methods, which cannot effectively avoid error accumulation during long-term operation. They also lack efficient compatibility solutions with different brands of PLCs (such as Siemens and Yaskawa), have insufficient data transmission stability, and cannot form a complete closed loop of "positioning signal acquisition-verification-application", making it difficult to support the needs of port automation operations. Utility Model Content

[0004] The purpose of this utility model is to provide an automatic calibration device for positioning gantry cranes in order to solve at least one of the above-mentioned technical problems.

[0005] This utility model provides an automatic positioning verification device for a quay crane, characterized in that it includes: an induction magnet assembly, a magnetic induction limit assembly, an absolute position encoder assembly, and a PLC connection assembly; wherein, the induction magnet assembly includes multiple induction magnets disposed on the marine survey track of the quay crane at the port berth; the magnetic induction limit assembly includes multiple adjustable brackets disposed on the quay crane trolley and a magnetic induction limit body disposed at the end of the adjustable brackets; the absolute position encoder assembly includes an absolute position encoder disposed on the side of the driven wheel of the quay crane trolley, a waterproof cover disposed above the absolute position encoder, and an optical fiber repeater device; the PLC connection assembly includes a programmable logic controller and a communication interface, the programmable logic controller being connected to the absolute position encoder and the magnetic induction limit body through the communication interface.

[0006] Optionally, the plurality of induction magnets are arranged at equal intervals in an embedded installation manner on the marine survey track, and the surface of the induction magnets is sealed with sealant.

[0007] Optionally, the adjustable bracket includes a transverse slide groove and a longitudinal adjusting bolt, and the magnetic induction limiting body is fixed in the transverse slide groove by the longitudinal adjusting bolt.

[0008] Optionally, the absolute position encoder includes a multi-turn absolute position encoder.

[0009] Optionally, the multi-turn absolute position encoder is coaxially arranged with the driven wheel of the quay crane.

[0010] Optionally, the waterproof housing has a wire hole on its side, through which the optical fiber of the optical fiber repeater passes and is connected to the absolute position encoder; the optical fiber repeater is also connected to the communication interface of the programmable logic controller.

[0011] This utility model provides an automatic calibration device for quay crane positioning. By combining magnetic induction limiters and absolute position encoders, it improves the positioning accuracy and reliability of quay cranes, while reducing equipment costs. It is suitable for complex port operating environments, meets the positioning data requirements of IGV operations and terminal production management systems, and alleviates the technical problems of insufficient positioning accuracy and error accumulation in existing technologies. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0013] Figure 1 A schematic diagram of an automatic positioning and calibration device for a quay crane trolley provided in an embodiment of this utility model; Figure 2 A schematic diagram of the structure of a magnetic induction limiting component provided in an embodiment of this utility model; Figure 3 This is a schematic diagram of the structure of an absolute position encoder assembly provided in an embodiment of the present invention.

[0014] In the diagram: 10. Induction magnet assembly; 11. Induction magnet; 20. Magnetic induction limit assembly; 21. Magnetic induction limit body; 22. Transverse slide; 23. Longitudinal adjusting bolt; 30. Absolute position encoder assembly; 31. Absolute position encoder; 32. Waterproof cover; 33. Fiber optic repeater device; 40. PLC connection assembly; 50. Quay crane trolley; 51. Driven wheel. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0016] Figure 1 This is a schematic diagram of an automatic positioning and calibration device for a quay crane according to an embodiment of the present utility model. Figure 1 As shown, the device includes: a sensing magnet assembly 10, a magnetic induction limit assembly 20, an absolute position encoder assembly 30, and a PLC connection assembly 40.

[0017] Specifically, the induction magnet assembly 10 includes a plurality of induction magnets 11 disposed on the marine survey track of the quay crane at the port berth. Preferably, the plurality of induction magnets 11 are disposed at equal intervals in an embedded manner on the marine survey track, and the surface of the induction magnets 11 is sealed with sealant.

[0018] For example, 75 induction magnets are installed on the seaside track of the berth quay crane, with an installation interval of 20 meters between adjacent induction magnets. The induction magnets are installed in an embedded manner, and their surfaces are sealed with waterproof sealant after installation. The protection level after sealing is not lower than IP65, so as to adapt to the humid and dusty environment of the port and provide stable multi-point position marking signals for the positioning of the trolley.

[0019] Specifically, the magnetic induction limiting component 20 includes multiple adjustable brackets disposed on the gantry crane trolley 50 and a magnetic induction limiting body 21 disposed at the end of the adjustable brackets.

[0020] Figure 2 This is a structural schematic diagram of a magnetic induction limiting component provided according to an embodiment of the present utility model. Figure 2 As shown, the adjustable bracket includes a transverse slide 22 and a longitudinal adjusting bolt 23. The magnetic induction limiting body 21 is fixed in the transverse slide 22 by the longitudinal adjusting bolt 23, and the end of the transverse slide 22 is fixed to the side of the quay crane trolley 50. The magnetic induction limiting body 21 is positioned directly above the induction magnet 11.

[0021] Preferably, the adjustable bracket is made of Q235 steel, the transverse slide 22 is 50mm long and 12mm wide, and the longitudinal adjusting bolt 23 is M12 with an adjustment stroke of 30mm. The transverse position is adjusted by sliding the longitudinal adjusting bolt 23 within the transverse slide 22, and the longitudinal height is adjusted by rotating the longitudinal adjusting bolt 23, ensuring precise engagement between the magnetic induction limit body 21 and the induction magnet 11, and stably triggering the position verification signal.

[0022] Specifically, the absolute position encoder assembly 30 includes an absolute position encoder 31 disposed on the side of the driven wheel 51 of the quay crane trolley, a waterproof cover 32 disposed above the absolute position encoder 31, and an optical fiber repeater 33.

[0023] Figure 3 This is a structural schematic diagram of an absolute position encoder assembly provided according to an embodiment of the present utility model. Figure 3 As shown, the absolute position encoder 31 includes a multi-turn absolute position encoder, which is coaxially mounted with the driven wheel 51 of the quay crane. A wiring hole is provided on the side of the waterproof cover 32, through which the optical fiber of the optical fiber repeater 33 passes and connects to the absolute position encoder 31.

[0024] In an optional embodiment of this utility model, the outer shaft end cover of the driven wheel 51 is modified to accommodate the central shaft (made of 45# steel, 50mm in diameter, and 30mm in length) of the absolute position encoder 31. The coaxiality error between the central shaft and the wheel axle is ≤0.1mm, ensuring that the absolute position encoder 31 rotates synchronously with the driven wheel 51. The waterproof cover 32 is made of 304 stainless steel (200mm×150mm×100mm, 2mm thick). The waterproof cover 32 has a cable hole (equipped with a waterproof connector) for fiber optic cable insertion on its side and is placed over the absolute position encoder 31. One end of the fiber optic repeater 33 is connected to the signal terminal of the absolute position encoder 31, and the other end is connected to the Siemens S1200 PLC system in the electrical room to ensure stable data transmission of the encoder.

[0025] Specifically, the PLC connection assembly 40 includes a programmable logic controller (PLC) and a communication interface. The PLC is connected to the absolute position encoder 31 and the magnetic induction limit body 21 via the communication interface. The fiber optic repeater 33 is also connected to the communication interface of the PLC.

[0026] Optionally, the programmable logic controller includes a Siemens S1200 PLC, model 1214C, and the communication interface includes the communication interface of the Yaskawa CP218. The Siemens S1200 PLC is used to receive position data collected by the absolute position encoder and the signal triggered by the magnetic induction limit switch, calculate the real-time position of the trolley, and realize data interaction with the Yaskawa CP218 through the communication interface. It is also connected to the touch screen in the driver's cab to display the trolley position information.

[0027] The installation process of the automatic calibration device for positioning of quay cranes provided in this embodiment of the utility model is as follows: 1. Installation and implementation of the induction magnet assembly: Before construction, 75 installation points for induction magnets were marked near the sea-side track of the port berth using a laser rangefinder (accuracy ±1cm), ensuring that the distance between adjacent installation points was 20 meters ±0.05 meters. Use a drilling machine to drill holes at the installation point, with the hole diameter matching the diameter of the induction magnet (50mm) and the drilling depth 80mm. Embed the induction magnet into the drilled hole, cover the exposed surface of the induction magnet with polyurethane waterproof sealant (apply 5mm thick), and let it stand for 24 hours to allow the sealant to fully cure. After curing, a water spray test (water pressure 0.3MPa, lasting 10 minutes) is used to check the seal integrity. Installation is completed after ensuring there is no leakage.

[0028] 2. Implementation of magnetic induction limit component installation: Based on the actual layout of the gantry cranes 1-4# and 13-20# on the sea side, a special adjustable bracket was welded and fixed to the lower surface of the gantry traveling beam near the sea side. The magnetic induction limiting body (model adapted to the requirements of quay crane operation) is fixed in the transverse sliding groove of the bracket with bolts; Manually move the quay crane to any position of the induction magnet, adjust the lateral position of the magnetic induction limit by sliding the lateral slide groove, and adjust the longitudinal height of the limit by rotating the longitudinal adjusting bolt. At the same time, use a multimeter to check the limit trigger signal (ensure that the output voltage is stable at 24V and the duration is ≥100ms). Repeat the adjustment until the magnetic induction limit can stably trigger a signal each time it passes the induction magnet, and finally tighten the bolt to fix the limit position.

[0029] 3. Installation and implementation of the absolute position encoder component: Disassemble the original shaft end cover of the right-side trolley driven wheel of the quay crane 1-4# trolley mechanism. Based on the installation dimensions of the absolute position encoder, process a new shaft end cover with a central shaft (the central shaft is made of 45# steel, with a diameter of 50mm and a length of 30mm). After processing, check the coaxiality between the central shaft and the wheel axle to ensure that the error is ≤0.1mm. A multi-turn absolute position encoder (1024 lines / turn resolution) is fitted onto the central shaft and fixed by a key connection to ensure that the encoder rotates synchronously with the wheel; A 304 stainless steel dustproof and waterproof cover is placed over the encoder. The cover is fixed to the outside of the shaft end cover with bolts. A waterproof connector is installed at the wire hole of the cover. The encoder's signal cable is passed through the waterproof connector and connected to the fiber optic repeater. The Siemens S1200 PLC connecting the fiber optic repeater to the electrical room was powered on to test the encoder data output. The pulse signal was observed with an oscilloscope to ensure that the resolution reached 1024 lines / revolution and that the data transmission was uninterrupted.

[0030] 4. Installation and debugging of PLC connection components: The Siemens S1200 PLC was installed in the electrical room of the quay crane 1-4#. The PLC was connected to the Yaskawa CP218 via communication cables and configured with the PROFINET communication protocol to ensure a data transmission rate of 100Mbps. Connect the PLC to the driver's cab touch screen, debug the touch screen display program, and ensure that the touch screen can display the trolley position coordinates (accuracy 0.001m) and magnetic induction limit trigger status in real time; Power on and run the quay crane trolley, test the stability of the PLC receiving encoder data and magnetic induction limit signals, calculate the real-time position of the trolley, and ensure that the position data update frequency is ≥10Hz with no data delay or loss.

[0031] The automatic positioning and calibration device for quay cranes provided in this embodiment of the invention has the following technical advantages compared with the prior art: 1. Strong environmental adaptability: The sealing treatment of the induction magnet and the dustproof and waterproof cover of the encoder are designed for the humid, dusty and salt spray environment of the port, reducing the equipment failure rate to ≤1 time every 3 months, ensuring long-term stable operation; 2. High positioning accuracy: The coaxial installation of the encoder and the wheel (coaxiality ≤ 0.1mm), the adjustable structure of magnetic induction limit, and the multi-point induction magnetic marking with a 20-meter interval effectively eliminate the accumulation of errors during the operation of the trolley, and the positioning error is controlled within ±5mm, which meets the positioning accuracy requirements of IGV. 3. Significant cost advantage: Compared to BTG's magnetic nail positioning solution of ≥200,000 yuan, the cost of a single set of hardware for this device (including induction magnet, magnetic induction limit, encoder, and bracket) is ≤60,000 yuan, reducing hardware procurement costs by 75% and maintenance costs by even lower. 4. Good compatibility: The PLC connection component enables stable communication between Siemens S1200 PLC and Yaskawa CP218, adapting to existing quay crane equipment without requiring large-scale replacement of existing hardware, reducing the difficulty and cost of modification.

[0032] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0033] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An automatic calibration device for positioning trolleys of quay cranes, characterized in that, include: The system comprises an induction magnet assembly, a magnetic induction limit assembly, an absolute position encoder assembly, and a PLC connection assembly. The induction magnet assembly includes multiple induction magnets mounted on the marine survey track of the quay crane at a port berth. The magnetic induction limit assembly includes multiple adjustable brackets mounted on the quay crane trolley and a magnetic induction limit body mounted at the end of each adjustable bracket. The absolute position encoder assembly includes an absolute position encoder mounted on the side of the driven wheel of the quay crane trolley, a waterproof cover mounted above the absolute position encoder, and a fiber optic repeater. The PLC connection assembly includes a programmable logic controller (PLC) and a communication interface, with the PLC connected to the absolute position encoder and the magnetic induction limit body via the communication interface.

2. The automatic calibration device for quay crane positioning according to claim 1, characterized in that: The plurality of induction magnets are installed at equal intervals on the marine survey track using an embedded installation method, and the surface of the induction magnets is sealed with sealant.

3. The automatic calibration device for quay crane positioning according to claim 1, characterized in that: The adjustable bracket includes a transverse slide groove and a longitudinal adjusting bolt, and the magnetic induction limiting body is fixed in the transverse slide groove by the longitudinal adjusting bolt.

4. The automatic calibration device for quay crane positioning according to claim 1, characterized in that: The absolute position encoder includes a multi-turn absolute position encoder.

5. The automatic calibration device for positioning of the quay crane trolley according to claim 4, characterized in that: The multi-turn absolute position encoder is coaxially mounted with the driven wheel of the quay crane.

6. The automatic calibration device for gantry crane positioning according to claim 1, characterized in that: The waterproof housing has a wire hole on its side, through which the optical fiber of the optical fiber repeater passes and is connected to the absolute position encoder; the optical fiber repeater is also connected to the communication interface of the programmable logic controller.

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