SYSTEM FOR CENTRAL CONTROL OF ONE OR MORE CRANES

Description

[0001] The invention relates to a system for the central control of one or more cranes. Currently, a tower crane is operated via a radio remote control or a control station in the crane cab mounted on the crane. The radio remote control is a remote control that the crane operator on the ground wears. To remotely control the crane, the crane operator must always maintain visual contact with the crane hook or the load; consequently, the crane operator must always walk with the load.

[0002] Large top-slewing cranes are typically operated from the control station in the crane cab. This control station offers the advantage of providing the crane operator with a good overview of the construction site and sufficient visual contact with the suspended load at all times. The control station strongly ties the crane operator to the machine, as they will only undertake the strenuous and time-consuming climb down from the crane during longer interruptions.

[0003] A system according to the preamble of claim 1 is known from JP 2002 274779A.

[0004] We are therefore looking for a system that allows a novel yet reliable and safe remote control of a crane.

[0005] This object is achieved by a system according to the features of claim 1. Advantageous embodiments are the subject of the dependent claims following the main claim.

[0006] According to claim 1, a system for the central control of one or more cranes is proposed, wherein the system comprises at least one crane and at least one central control station. The at least one crane comprises one or more image sensors designed to observe a picked-up load, at least part of the crane's surroundings, and at least part of the crane structure. The arrangement of the image sensors preferably allows detection of at least all movable crane components, ideally the entire crane structure. For example, image sensors are provided that are attached to a trolley and / or a slewing platform and / or the load hook or can detect at least these crane components. The installation of external screens further improves the crane operator's visibility.

[0007] Furthermore, at least one bidirectional communication connection between the crane and the central control station is provided to transmit the generated image sensor data to the central control station. At least one display element is provided on the control station side, enabling a visual representation of the received image data. Furthermore, the central control station comprises one or more input devices for inputting control commands, which can be transmitted via the existing communication connection to one or more crane actuators and / or the crane control system of the connected crane for executing crane movements.

[0008] The inventive arrangement of the individual image sensors on the crane provides the crane operator with a sufficient field of vision to constantly observe the necessary components of the crane and the surrounding area. The crane operator no longer needs to have direct visual contact with the crane or the surrounding area; it is sufficient to observe the information shown on the display element. The positioning of the control station is therefore no longer subject to restrictive conditions; instead, it is sufficient to ensure a stable and, if possible, delay-free communication connection between the crane and the control station. In particular, this makes it possible to integrate the central control station into an office container or similar building, preferably located centrally on a large construction site. From this location, the construction machinery or cranes to be controlled on the large construction site can be remotely controlled.

[0009] According to the invention, the control station is further enhanced with a pair of data glasses and a connection interface for the data glasses. This allows the received sensor data from the image sensors to be displayed to the crane operator via the data glasses. The image sensors can be activated by controlling the glasses' movements.

[0010] To enable realistic monitoring of the crane structure, the surroundings, and the load, it is particularly advantageous if the individual image sensors are designed as stereo cameras. This allows stereoscopic image information to be generated and transmitted to the central control station. In this configuration, it is further advantageous if one or more display elements of the central control station are designed as 3D monitors to provide the crane operator with the most vivid and realistic monitoring display possible. This allows for better estimation of distances between crane components and surrounding objects.

[0011] Furthermore, according to an advantageous embodiment, at least one crane can be equipped with one or more audio sensors that record crane noises and / or ambient noise on the construction site. Audio sensors on the load hook allow the crane operator to communicate with personnel on the ground. Automatic voice recognition can then, if desired, recognize predefined crane control commands (e.g., "emergency stop") and initiate appropriate measures. These audio signals can also be transmitted to the central control station via the communication link, where they can be used for enhanced image analysis or simple playback via loudspeakers.

[0012] In addition to the image sensors and audio sensors, the crane can be equipped with additional sensors, for example, to detect external environmental influences such as rain sensors, air sensors, temperature sensors, wind sensors, distance sensors, etc. These environmental factors are also recorded using sensors and transmitted as sensor data to the central control station via the bidirectional communication connection.

[0013] A monitoring device installed in the control station and / or in the control cabinet records the received data streams from the image sensors, audio sensors and other sensors and prepares them for display on the display element.

[0014] Furthermore, it is conceivable that the sensor data from all other sensors installed on the crane could also be transmitted to the central control station. This includes, for example, any sensors on the actuators to determine their specific position. Furthermore, the data from any pressure, force, motion, and / or distance sensors can be transmitted to the central control station to record the current operating status of the crane as completely as possible.

[0015] To control the visual surveillance area, one or more image sensors or stereo cameras can be automatically focused using an adaptive control system or can be activated by control commands entered at the control station. In particular, the image sensors or stereo cameras are mounted on the crane structure in an adjustable, ideally pivotable manner. Furthermore, adjustment or pivoting devices are provided that can be activated by control commands entered at the central control station.

[0016] It is particularly expedient if control commands for activating the image sensors or stereo cameras can be input via one or more foot pedals and / or foot contacts on the control station. In a specific embodiment, it is conceivable that a continuous panning movement and / or a continuous zooming of the image sensors or stereo cameras is enabled by actuating at least one foot pedal on the control station. Furthermore, switching between different available image sensors or stereo cameras may be necessary. Switching from a first image sensor to a second image sensor is expediently carried out by actuating at least one foot contact on the control station.

[0017] In an optional design, adjustment or swivel movement of individual sensors or cameras can be carried out via a head movement of the crane operator.

[0018] In addition to the display elements for displaying the image data, at least one additional display element can be provided that enables a display of the machine data required for crane operation, as is familiar from the crane cab. In addition to the usual machine data, additional information can also be provided via the monitor. It is particularly advantageous if the central control station has a communication interface to at least one external database, via which, for example, operating instructions and / or circuit diagrams and / or technical information and / or service information about the crane to be controlled can be retrieved and then displayed on the display element of the central control element.

[0019] Furthermore, a further communication interface between the central control station and a central order management system can be provided. Via this interface, order-specific data can be retrieved from the central order management system or received via this system. An order module in the central control station is used to evaluate the received order. The order module checks the movement sequence of the crane required for the order. As part of this check, it is determined, for example, whether the crane is fundamentally suitable for order processing, i.e. whether it has the necessary performance characteristics to handle the order. The order module can then, for example, mark the received orders as feasible or not feasible. Processed orders are reported back. Furthermore, disruptive influences, such as strong winds, can also be reported back to the construction site control computer.

[0020] It is also conceivable that the task module could be designed in such a way that obstacles in the crane's vicinity can be identified using image sensors and taken into account when assessing the feasibility of a task. This would allow not only the crane's performance characteristics but also the crane's surroundings to be checked to determine whether the task can be completed without environmental interference.

[0021] For example, it is conceivable that an order marked as unexecutable is discarded by the order module, or the order is split and the follow-up order is forwarded to a linked crane. Furthermore, it is possible for received orders that have been deemed feasible by the order module to be executed at least partially automatically by an integral crane control unit of the central control station. In this case, the crane control unit of the central control station intervenes directly in the control of the crane, taking the order into account. In particular, the crane control unit of the control station communicates with the machine's crane control system and / or directly with the crane actuators.

[0022] For automated crane control, it is also advantageous if at least one tracking device is installed on the crane to communicate the crane's current position to the central control station. Suitable tracking devices include, for example, a GPS or DGPS receiver, which continuously or cyclically communicates the crane's geographical position to the control station.

[0023] Furthermore, it is desirable that the crane load hook be equipped with at least one tracking device to record the geographical hook position during crane operation and to communicate this to the central control station. The tracking device of the crane load hook can also be configured as a GPS or DGPS receiver. In principle, the (D)GPS receiver on the crane load hook can also be used to record the crane's position and communicate it to the control station. Distance sensors assist the crane operator in precisely positioning the load and help stop the crane drive in time if there is a risk of collision.

[0024] The central control station can be equipped with a monitoring device that evaluates the geographical position data of the hook and, based on this, generates the necessary control commands to compensate for any load vibrations. The generated control commands are transmitted from the control station to the crane control system or directly to the actuators to be controlled. This enables external, optional, superimposed active vibration damping of the load, implemented by the central control station.

[0025] Furthermore, the monitoring device can be configured to implement external collision monitoring. Received position data of the crane and / or the load hook can be evaluated by the monitoring device in conjunction with data received from the image sensors in order to detect impending collisions between the crane and any interfering edges on the construction site at an early stage. In the event of an impending collision, the monitoring device influences the crane control system via the crane control unit of the control station. For this purpose, appropriate control signals are transmitted from the control station and to the crane to throttle the crane movement and / or to emergency-stop crane operation.

[0026] In addition to the system according to the invention, the present invention also relates to a crane, in particular in the form of a tower crane, crawler crane, or mobile crane, for a system according to the present invention. The crane is therefore characterized by the same advantages and properties as the system according to the invention, which is why a repetitive description is omitted here.

[0027] Finally, the invention relates to a central control station for a system according to the present invention, wherein the control station is suitable for the central control of one or more cranes. The central control station is therefore also characterized by the same advantages and properties as already explained above with reference to the system according to the invention. For this reason, a repetitive description is omitted.

[0028] The crane cameras can be used for construction site surveillance. Their functional areas include preventing unauthorized entry to the construction site, theft protection, and accident logging.

[0029] A special algorithm in the IPC analyzes the camera data and evaluates the situations for unusual events. Depending on the situation detected on the construction site, a corresponding message is generated and communicated to a higher-level control system. Within the control system, the message can be communicated to the responsible security personnel or the owner via email, SMS, or a social network, depending on the desired link.

[0030] Furthermore, camera data / images can be transmitted to the control system via a modem to assess the construction site situation.

[0031] Further advantages and features of the invention will be explained in more detail below with reference to an embodiment shown in the single figure.

[0032] The single figure shows schematically components of the overall system and their necessary communication connection with each other.

[0033] The data glasses are not shown in the figure.

[0034] The central element is a central radio-controlled crane control station 10, the core component of which is an industrial PC (IPC) 11. In terms of its crane functions, the independent control station 10 is almost identical to the control station in the crane cabin of a crane 20, 21 (tower crane) to be controlled.

[0035] The central control station 10 can be housed in an office container on the construction site and is used for remote control of at least one crane 20, 21. The structure of the control station 10 also consists of several control elements 12, such as control levers, switches and buttons, a 3D-capable monitor 13 for visual crane monitoring, a monitor 14 for displaying the machine data and a monitor 14 for order monitoring.

[0036] The crane 20, 21 is provided with a stereo camera system 22, whose individual cameras are pivotably mounted on the crane structure. Furthermore, the camera lenses can be zoomed in. The stereo camera system is used to observe the crane 20, 21, in particular the load, the trolley, and the slewing platform, as well as its surroundings. Furthermore, audio sensors and other sensors are provided to detect crane movements and crane conditions. The audio sensors generally record ambient noise, but operating noises caused by the crane's operation are also recorded. An audio sensor on the load hook serves to prevent accidents and communicate with the slinger. The other sensors, such as pressure sensors, force sensors, position sensors, slewing gear sensors, rope sensors, etc., correspond to the sensors typically used on the crane for crane control. These sensor signals are also to be transmitted to the central control station.Finally, a DGPS sensor 23 is available on the load hook, the position data of which is also transmitted to the control station 10.

[0037] A bidirectional radio connection exists between crane 20, 21 and control station 10, for transmitting the monitor or sensor data wirelessly to control station 10 and, in the opposite direction, for sending the crane control commands generated in control station 10 to the addressed crane 20, 21. This includes control signals for actuator operation, but also signals used to configure and align the aforementioned sensors 22.

[0038] The crane environment of the crane 20, 21 is displayed on the 3D-capable monitor 13 of the control station 10. This area includes the view of the load, the construction site, and the crane 20, 21. Furthermore, crane movements, audio signals, and environmental factors are evaluated and displayed by a monitoring device of the control station 10. The industrial PC (IPC) 11 installed in the control station 10 records the data streams from the cameras 22, crane sensors, and environmental sensors. Special algorithms prepare the camera data for display on the 3D-capable monitor 13. The sensor data is also recorded, processed, and displayed as superimposed images or thumbnails on the monitor 13. External or integrated speakers of the monitor 13 reproduce the audio signals of the crane 20, 21 at the control station.

[0039] From the control station 10, the crane operator can pan the stereo cameras 21 in all directions and zoom in on the images accordingly. The autofocus function of the cameras 21 assists the operator in this process. The camera functions are controlled via an adaptive control system integrated into the control station and / or foot pedals 12 and foot switches 12. The foot pedals 12 enable continuous panning and zooming of the cameras 22. The foot switches are used to switch the cameras 22 between the trolley, slewing platform, and load hook.

[0040] This enables the crane operator to correctly assess the situation on the construction site and control the resulting crane movements very precisely.

[0041] By using data glasses, the swiveling stereo cameras can be controlled via head movements.

[0042] The crane monitor (EMS) 14 provides the crane operator with all the usual information and functions, including control and operation, which are also displayed on the monitor in the crane cab. Since the size of the monitor 14 is no longer limited, larger monitors 14 can be used. This allows crane-specific documents linked to the higher-level LIDAT system 40 to be displayed. Crane-specific documents include operating instructions, circuit diagrams, technical information, and service information. This data can be accessed as needed from a TC portal 41 via an existing internet connection at the control station 10 or indirectly via the LIDAT machine portal 40.

[0043] The system also includes automated order management. A central construction control station 30 transmits the transport orders, including GPS construction site target coordinates, to the order management system of control station 10. The IPC 11 contains an evaluation module with a special algorithm that calculates and checks the order's movement sequence and offers the crane operator a partially automated sequence (autopilot) before the order is processed. If the order cannot be processed (e.g., if the load or reach is exceeded), the order is marked as unfeasible. Since the crane cameras 22, in conjunction with the collision monitoring system of control station 10, can also detect obstacles, a fully automated movement sequence is also possible. The crane control unit of control station 10 generates the necessary control commands, which are then transmitted to the respective crane.

[0044] This also allows for a crane call function if the crane 20, 21 is equipped with a radio panel with a built-in DGPS receiver 23. Large construction sites will likely be simulated virtually first in the future. The movement sequences of a job can be checked virtually, via a real or virtual control station (web service) in the IPC 11. The necessary crane data such as load, radius, etc. can be obtained either directly from the crane or from the crane configurator via a link to the Liebherr portal "LIDAT" 40.

[0045] In the IPC 11, the GPS coordinates of the load hook can also be calculated using a correction signal. The calculated coordinates are very precise and can therefore be used to control vibration-damping crane movements, which are generated by the crane control unit of control station 10 and transmitted to the respective cranes 20, 21. Differential GPS means that the normal GPS signal is calculated using a correction signal to produce a very precise DGPS signal.

[0046] In the IPC 11, the collision monitoring system compares the DGPS coordinates of the load hook with other disruptive movements detected by the cameras and, if necessary, initiates safe measures. In critical areas, the speed of the crane's movements is reduced, and in an absolute emergency, before a collision occurs, the crane is shut down with an emergency stop signal.

Claims

1. System for central control of one or more cranes, including at least one crane and at least one central control station, wherein the crane includes one or more image sensors for observing a picked-up load, at least part of the crane surroundings and at least part of the crane structure, the crane is connected to the control station via at least one bidirectional communication link for the transmission of the image sensor data, and wherein the control station comprises at least one display element for the visual representation of the received sensor data as well as provides at least one input device for inputting control commands, and the control commands can be transmitted via the communication link to one or more crane actuators and / or the crane control for performing crane movements characterized in that the system comprises smart glasses and the control station comprises a connection interface for smart glasses, wherein the displaying of the sensor data of the image sensors / stereo cameras is effected via the smart glasses, and the image sensors can be actuated through movements of the glasses.

2. System according to claim 1, characterized in that the one or multiple image sensors are stereo cameras and the display element is at least a 3D-capable monitor.

3. System according to any one of the preceding claims, characterized in that the crane comprises one or multiple audio sensors for the detection of noise of the crane and / or of the surroundings and / or environmental sensors for the detection of environmental influences, wherein this sensor data can be forwarded to the central control station and the control station comprises one or multiple audio speakers for the replay of received audio signals.

4. System according to any one of the preceding claims, characterized in that signals of other sensors of the crane, e.g. pressure sensors, position sensors for the detection of the position of crane components or crane actuators, are receivable via the control station, and the control station comprises a monitoring means for the evaluation of the crane movements performed based upon this sensor data.

5. System according to any one of the preceding claims, characterized in that the image sensors or the stereo cameras can be actuated by means of control commands that can be input at the control station, in particular the image sensors or stereo cameras are mounted on the crane in an adjustable, ideally pivotable manner, wherein the adjustment or pivoting movement can be performed by a control command which can be input at the control station.

6. System according to claim 5, characterized in that the control commands for actuating the image sensors / stereo cameras can be input via one or multiple foot pedals and / or foot contacts of the control station, wherein, preferably, a continuous pivoting movement and / or a zooming of the image sensors / stereo cameras is effected by actuating at least one foot pedal of the control station and / or a switching between available image sensors / stereo cameras of the crane by actuating at least one foot contact of the control station.

7. System according to any one of the preceding claims, characterized in that the image sensors / stereo cameras can be adjusted or pivoted through movements of the glasses.

8. System according to any one of the preceding claims, characterized in that at least one further display element is provided to display machine data or sensor data and / or operating instructions and / or circuit plans and / or technical and / or service information.

9. System according to any one of the preceding claims, characterized in that the control station includes an interface for receiving task-specific data from a central task management, and a task module for the evaluation of the received task is provided, wherein the task module checks the crane's motion sequence required for the task and marks the task as feasible or non-feasible.

10. System according to claim 9, characterized in that the task module is configured in such a way that obstacles are discernible based upon the image sensors and are considered for the evaluation of the feasibility of a task.

11. System according to any one of claims 9 or 10, characterized in that the control station includes a crane control unit, which transmits controls signals to the crane upon a positive evaluation of the received task, in order to perform at least a part of the motion sequences of the crane in an automated manner.

12. System according to any one of the preceding claims, characterized in that the crane includes at least one positioning means, in particular a GPS or DGPS receiver, and the geographical crane position can be communicated to the control station.

13. System according to any one of the preceding claims, characterized in that the crane load hook is equipped with at least one positioning means, in particular a GPS or DGPS receiver, and the geographical hook position can be communicated to the control station, wherein the crane control unit of the control station generates necessary crane commands based on the transmitted position of the load hook and transmits it to the crane, in order to compensate potential load oscillations.

14. System according to any one of the preceding claims, characterized in that the control station includes a collision monitoring means, which evaluates the received position data of the crane and / or the load hook and recognizes potential collisions of the crane with interfering edges in consideration of the received data of the image sensors, wherein, if a collision is imminent, preferably, a control signal is transmittable from the crane control unit of the control station to the crane to decelerate the crane movements and / or for an emergency stop of the crane operation.