Container Crane Control Device

Abstract

To provide a container crane control system capable of easily avoiding collision of a container.SOLUTION: A container crane control system according to the present embodiment comprises a master control device and a collision prevention device. The master control device includes: swing information calculation means to calculate a rope swing angle; speed control means to supply a first speed reference to a motor driving device; and swing suppression control means to output a second speed reference generated, replacing the first speed reference, so as to reduce the rope swing. The collision prevention device comprises: obstacle detection means to detect obstacles; obstacle distance calculation means to calculate an obstacle distance; deceleration distance time calculation means to calculate a traveling distance of a cargo based on the speed references; and collision prevention logic calculation means to generate a command for stopping the cargo based on the obstacle distance and the traveling distance, and to output the command to the speed control means.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] Embodiments of the present invention relate to a container crane control device.

Background Art

[0002] An operator who operates a container crane operates a main controller, for example, an operation lever, to lift a container placed in an onshore container yard and load the lifted container onto a container ship. Alternatively, the operator operates the main controller to lift a container loaded on a container ship and move it to an onshore container yard for placement. Although the operator moves the container with great care, there is a rare case where an accident occurs in which the suspended container collides with a stack of loaded containers.

[0003] Therefore, a container crane control device may be equipped with a collision prevention device that detects the shape of a stack of containers and automatically stops the movement of the container when approaching the stack of containers. For such a collision prevention device, for example, the technology of Patent Document 1 is known.

[0004] An operator skilled in operating a container crane may try to shorten the time for lifting and moving by moving the container horizontally while lifting it. In a large container crane installed in a port or the like, since the length of the rope for lifting the container is long, if the container is moved horizontally while being lifted, the container may swing. Even an experienced operator is likely to cause a collision accident if moving with the container swinging.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] An embodiment of the present invention aims to provide a container crane control device that can easily avoid collisions of containers.

Means for Solving the Problems

[0007] An embodiment of the present invention includes: swing information calculation means for calculating a swing angle of a rope hanging a load based on an output from a swing width sensor and based on a swing width of the rope; speed reference calculation means for sequentially calculating and outputting a first speed reference for horizontal movement of the load based on an operation of an operator; and speed control means for sequentially outputting a second speed reference for horizontal movement of the load to a motor drive device that drives a motor for horizontally moving the load so as to reduce the swing of the rope based on the swing angle when the first speed reference output from the speed reference calculation means or a deceleration command for starting deceleration of the load is input, and for configuring a preset speed control pattern. A main control device; obstacle detection means for detecting an obstacle existing in a direction in which the load travels; obstacle distance calculation means for sequentially calculating and outputting an obstacle distance that is a horizontal distance between the load and the obstacle; deceleration stop distance calculation means for sequentially calculating and outputting a deceleration stop distance from the start of deceleration to the stop of horizontal movement of the load based on the first speed reference and the second speed reference; and collision prevention logic calculation means for generating the deceleration command based on the obstacle distance and the deceleration stop distance and outputting the deceleration command to the speed control means. The swing information calculation means generates an alarm transmission command for notifying the operator that the rope is swinging when the swing angle is greater than or equal to a first threshold value.

Advantages of the Invention

[0008] According to the embodiment, a container crane control device that can easily avoid collisions of containers is provided.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Embodiments for Carrying Out the Invention

[0010] Hereinafter, each embodiment will be described with reference to the drawings. Note that the drawings are schematic or conceptual, and the relationships between the thickness and width of each part, the ratio of the sizes between parts, etc. are not necessarily the same as the actual ones. Also, even when representing the same part, there may be cases where their dimensions and ratios are shown differently in the drawings. In the present specification and each figure, elements that are the same as those described above with respect to the previously presented figures are denoted by the same reference numerals, and detailed descriptions thereof are omitted as appropriate.

[0011] FIG. 1 is a schematic side view illustrating a container crane to which the container crane collision prevention control device according to each embodiment is applied. As shown in FIG. 1, the container crane is installed so as to be movable on rails laid substantially parallel to the quay wall. A container ship 4 for loading containers is moored to the quay wall. The container crane can move along the quay wall on the running rails. In FIG. 1, the moving direction of the container crane is from the front to the back or from the back to the front of the paper surface.

[0012] The container crane has a girder provided via a column on a sill beam 5 provided parallel to the running rails. The girder is arranged substantially perpendicular to the running rails and extends up to the container ship 4. A trolley 8 is provided on the girder. The trolley 8 can move (travel seaward) seaward and move (travel landward) landward along the girder. Hereinafter, the seaward or landward direction may be referred to as the horizontal direction. Also, the horizontal movement of the trolley 8 and the container 2 may be referred to as horizontal movement.

[0013] The trolley 8 suspends the spreader 1 via a rope 7. The spreader 1 can hold the container 2. Hereinafter, the lifting and lowering direction of the goods including the spreader 1 and the container 2 suspended from the spreader 1 may be referred to as the vertical direction, and the movement in the vertical direction may be referred to as vertical movement. Also, the hoisting direction of the spreader 1 and the container 2 may be referred to as upward, and the lowering direction may be referred to as downward. Also, hereinafter, unless otherwise specified, the spreader 1 is described as holding the container 2.

[0014] In this example, a machine room is installed on the land side of the gantry. The machine room houses electrical equipment such as a motor for horizontally moving the trolley 8 along the gantry and a motor for winding up the rope 7. An electrical room 10 is also provided in the machine room, and the electrical room 10 houses a motor drive device for driving the motor and the like.

[0015] A driver's cab 9 is provided below the trolley 8. An operator 12 (Fig. 2) who operates the container crane boards the driver's cab 9 and operates the main controller 13 (Fig. 2) and the like arranged in the driver's cab 9 to operate the horizontal and vertical movements of the container 2.

[0016] On the land side where the container crane is installed, the chassis 6 of the trailer for transporting the container 2 is arranged. The container crane lifts the container 2 placed on the chassis 6 via the spreader 1, moves it to the container ship 4, and places it at a desired position on the container ship 4.

[0017] In this example, a plurality of containers are loaded on the container ship 4. Hereinafter, the container loaded on the container ship 4 is referred to as a placed container 3. The stacks of the placed containers 3 have various heights depending on the loading locations of the respective placed containers 3. Hereinafter, the horizontal position is simply referred to as the position. The stack of the placed containers 3 is the highest at the position PA near the center in the width direction of the container ship 4, with a height of HA. The stack of the placed containers 3 has a height of HB at the position PB from the land, and the height HB is slightly lower than the height HA. At the position PC farthest from the land, it has a lower height of HC. At the position PD between the position PA and the position PB, it has a height of HD that is lower than the height HB and higher than the height HC.

[0018] Note that the reference positions and heights can be arbitrarily set to appropriate values. For example, the reference position can be the position of the sea - side tip of the spreader 1 or the sea - side tip of the container 2 at the point where the horizontal movement of the container 2 starts. For example, the reference height can be the height of the lower surface of the container 2 at the point where the vertical movement of the container 2 starts. The position of the tip and the height of the lower surface of the container 2 are detected by, for example, the profile detection sensor 11. Hereinafter, unless otherwise specified, the term "position" refers to the position from the position of the sea - side tip of the container 2, and the term "height" refers to the height from the lower surface of the container 2.

[0019] The container crane control device of each embodiment detects the height and position of the placed container 3, and sequentially calculates the obstacle distance, which is the distance between the container 2 and the placed container 3. The container crane control device calculates the deceleration stop distance from the start to the stop of the horizontal movement of the container 2. The container crane control device monitors whether the obstacle distance is less than or equal to the deceleration stop distance. When the obstacle distance becomes less than or equal to the deceleration stop distance, regardless of the operation of the operator 12, the container crane control device starts the deceleration of the horizontal movement of the container 2 and stops the container 2. The container crane control device decelerates the horizontal movement of the container 2 at a predetermined deceleration rate to prevent the container 2 from colliding with the placed container 3 or other obstacles. Note that the horizontal movement of the container 2 in the deceleration stop distance is not limited to decelerating and stopping at a predetermined deceleration rate, and may be decelerated to a predetermined minimum speed at a predetermined deceleration rate. Hereinafter, unless otherwise specified, the deceleration stop distance is the distance from when the container 2 starts to decelerate until it stops.

[0020] The profile detection sensor (obstacle detection means) 11 is provided to detect the mounds of the placement container 3 and other obstacles. In this example, the profile detection sensor 11 is arranged at the tip of the trolley 8 and detects obstacles (hereinafter simply referred to as obstacles) including the mounds of the placement container 3 in the direction in which the trolley 8 travels on the sea. The container crane control device controls the horizontal movement and vertical movement of the container 2 based on the information detected by the profile detection sensor 11.

[0021] (First Embodiment) FIG. 2 is a schematic block diagram illustrating a container crane control device according to the first embodiment. As shown in FIG. 2, the container crane control device 100 according to the present embodiment includes a collision prevention device 102 and a main control device 16. The collision prevention device 102 and the main control device 16 are communicably connected to each other. In the container crane control device 100, an operator 12 boarding in the driver's cab 9 operates the main controller 13 while visually observing the display device 15 installed in the driver's cab 9 and the mounds of the placement container 3 which is the destination of the movement of the container 2 from the driver's cab 9, etc., to move and place the container 2 at the target position. The main controller 13 has, for example, an operation lever or the like. By tilting the operation lever of the main controller 13 back and forth, the container 2 moves at a speed corresponding to the tilted angle.

[0022] The collision prevention device 102 has a profile detection sensor 11, a swing width detection sensor 11a, an obstacle distance calculation function 17, a deceleration distance time calculation function 18, and a collision prevention logic calculation function 19.

[0023] The profile detection sensor 11 is, for example, an optical sensor. The profile detection sensor 11 scans the obstacles on the sea side of the container 2 to detect the profile of the obstacles. When scanning the obstacles, the profile detection sensor 11 scans the suspended container 2 to detect the position and height of the tip of the container 2. The profile of the obstacle is data representing the contour of the obstacle. The profile of the obstacle is, for example, a set of coordinates of the position and height of the obstacle. The profile detection sensor 11 outputs the detected profile of the obstacle and the position and height of the container 2 to the obstacle distance calculation function 17.

[0024] The swing width detection sensor 11a is provided, for example, on the trolley 8 so as to be able to detect the swing width of the rope 7. The swing width detection sensor 11a is, for example, an optical sensor, which detects the swing width of the rope 7 and outputs the detection result to the main control device 16.

[0025] The obstacle distance calculation function (obstacle distance calculation means) 17 sequentially calculates the obstacle distance using the profile of the obstacle output from the profile detection sensor 11 and the position of the tip of the container 2. The obstacle distance is the distance from the position of the tip of the container 2 to the position of the obstacle. The obstacle distance calculation function 17 sequentially outputs the calculated obstacle distance to the collision prevention logic calculation function 19. The obstacle distance calculation function 17 may display the profile of the obstacle or the like in the display device 15 installed in the cab 9 as in this example.

[0026] The deceleration distance time calculation function (deceleration stop distance calculation means) 18 sequentially calculates the deceleration stop distance, which is the moving distance of the container 2 from the start of deceleration to stop, using the value of the speed reference of the horizontal movement of the container 2 output from the main control device 16. As will be described later, the deceleration rate is set in advance, and the speed control pattern when the swing information is detected is calculated using a predefined swing suppression control arithmetic expression. The deceleration distance time calculation function 18 sequentially outputs the calculated horizontal deceleration stop distance of the container 2 to the collision prevention logic calculation function 19.

[0027] The collision prevention logic arithmetic function (collision prevention logic arithmetic means) 19 sequentially compares the obstacle distance and the deceleration stop distance. When the obstacle distance becomes less than or equal to the deceleration stop distance, the collision prevention logic arithmetic function 19 outputs a deceleration command for starting the deceleration of the container 2 to the main control device 16.

[0028] The main control device 16 includes a speed reference arithmetic function 20, a speed deceleration control function 21, a swing information detection arithmetic function 23, and a swing suppression control function 24.

[0029] One main controller 13 is installed on each side of the operator 12. To move the trolley 8 horizontally, the operator 12 operates one main controller 13, and to move the trolley 8 vertically, the operator 12 operates the other main controller 13. The operator 12 adjusts the speed of the horizontal movement and the vertical movement of the trolley 8 by adjusting the angle of the lever of each main controller 13.

[0030] The speed reference arithmetic function (speed reference arithmetic means) 20 calculates a speed reference according to the angle information of the lever using information on the speed corresponding to the angle information of the lever output from the main controller 13. The speed reference arithmetic function 20 outputs the calculated speed reference (first speed reference) to the speed deceleration control function 21.

[0031] The speed deceleration control function 21 outputs the speed reference sequentially calculated by the speed reference arithmetic function 20 to the motor drive control function 22. The speed deceleration control function 21 has an acceleration rate and a deceleration rate set in advance. When setting the angle of the main controller 13 or decelerating during a deceleration command, the preset acceleration rate and deceleration rate are applied and sequentially output as the speed reference.

[0032] The speed deceleration control function (speed control means) 21 outputs the speed reference to the motor drive control function 22 and also outputs it to the deceleration distance-time calculation function 18 of the collision prevention device 102. Needless to say, the speed reference calculation function 20 and the speed deceleration control function 21 calculate and output the speed reference for horizontal movement and the speed reference for vertical movement respectively. Each of the output speed references is supplied to the motor drive for horizontal movement and the motor drive for vertical movement.

[0033] The swing information detection calculation function (swing information calculation means) 23 uses the swing amplitude of the rope 7 detected by the swing amplitude detection sensor 11a to calculate information on the swing of the rope 7 and outputs it to the swing suppression control function 24. The information on the swing includes at least the swing angle of the rope 7, and preferably includes the swing period and the like. In order to calculate the swing period, the length of the rope 7 is used, and the length of the rope 7 is calculated, for example, based on the vertical movement distance of the container 2.

[0034] The swing suppression control function (speed control means) 24 outputs a speed control pattern for suppressing the swing based on the calculated information on the swing. The speed control pattern is generated according to the conditions when the swing occurs. The conditions when the swing occurs are, for example, the horizontal movement speed, the rope length, the direction and magnitude of the swing, the swing speed, and the like. The speed control pattern is calculated by inputting these conditions into a swing suppression control arithmetic expression defined in advance. The speed control pattern consists of, for example, a period of traveling at a constant speed and a period of traveling at a constant deceleration rate. More specifically, the speed control pattern is configured to be able to output a traveling pattern in which it travels at a constant deceleration rate in the first predetermined period, travels at a constant speed in the next predetermined period, and travels at a constant deceleration rate in the last predetermined period. Note that the swing suppression control arithmetic expression for calculating the speed control pattern may be set and implemented with an appropriate arithmetic expression for each crane implementing the main control device, or may be an appropriate arithmetic expression for each embodiment including other embodiments described later.

[0035] The swing suppression control function 24 outputs a speed control pattern to the speed deceleration control function 21. The swing suppression control function 24 outputs a speed reference (second speed reference) according to a speed control pattern for suppressing the swing of the rope 7.

[0036] The deceleration distance time calculation function 18 calculates the deceleration stop distance using the calculated speed control pattern.

[0037] The motor drive control function 22 is a control function for a motor drive device that drives the motors for horizontal movement and vertical movement of the trolley 8, respectively. The motor drive control function 22 inputs information on the speed of the motor from a speed sensor provided in the motor, and controls the output torque to the motor so that the speed of the motor follows the speed reference.

[0038] The main control device 16 and the collision prevention device 102 are realized by, for example, a programmable logic controller (PLC). Each of the above-described functions is realized by software, and is realized by combining one or more steps constituting the control program of the PLC and cooperating with hardware resources such as the profile detection sensor 11 and the main controller 13.

[0039] FIG. 3 is an example of a flowchart for explaining the operation of the container crane control device 100 according to the first embodiment. The operation of the container crane control device 100 according to the present embodiment will be described with reference to FIG. 3. As shown in FIG. 3, in step S31, the obstacle distance calculation function 17 sequentially calculates the obstacle distance based on the position of the tip of the container 2 and the position of the obstacle detected by the profile detection sensor 11, and outputs it to the collision prevention logic calculation function 19.

[0040] In step S32, the amplitude detection sensor 11a detects the amplitude of the rope 7 and outputs it to the vibration information detection arithmetic function 23. The vibration information detection arithmetic function 23 calculates the vibration angle of the rope 7 based on the amplitude of the rope 7. The vibration information detection arithmetic function 23 integrates the vertical movement speed of the container 2 to calculate the length of the rope 7. The vibration information detection arithmetic function 23 calculates the vibration period of the container 2 using the calculated vibration angle and length of the rope 7.

[0041] In step S33, based on the calculated vibration angle, vibration period, etc., the vibration suppression control function 24 calculates a speed control pattern for suppressing vibration and outputs it to the speed deceleration control function 21.

[0042] In step S34, based on the speed reference output by the speed deceleration control function 21 and the speed control pattern output by the vibration suppression control function 24, the deceleration distance time arithmetic function 18 calculates the deceleration stop distance of the container 2. Specifically, the deceleration distance time arithmetic function 18 calculates and outputs the time integral value of the speed when decelerating according to the speed control pattern applied at the speed reference at that time as the deceleration stop distance.

[0043] In step S35, the collision prevention logic arithmetic function 19 compares the obstacle distance with the deceleration stop distance. When the obstacle distance is less than or equal to the deceleration stop distance, the collision prevention logic arithmetic function 19 outputs a deceleration command to the main control device 16 and transfers the process to the next step S36. When the obstacle distance is longer than the deceleration stop distance, the collision prevention logic arithmetic function 19 returns the process to step S32 and repeats the above process.

[0044] In step S36, based on the deceleration command output from the collision prevention logic arithmetic function 19 of the collision prevention device 102, the speed deceleration control function 21 applies a preset deceleration rate or speed control pattern to the speed reference and sequentially outputs the applied speed reference to the motor drive control function 22. When a speed control pattern is input, the speed deceleration control function 21 gives priority to applying the speed control pattern over the deceleration rate.

[0045] In this way, even if the container 2 in motion sways, the container crane control device 100 according to this embodiment can prevent the container 2 from colliding with an obstacle by applying a speed control pattern corresponding to the sway.

[0046] The effects of the container crane control device 100 according to this embodiment will be described. The container crane control device 100 according to this embodiment includes a main control device 16 having a sway information detection calculation function 23 and a sway suppression control function 24. Based on the sway amplitude of the rope 7 detected by the sway amplitude detection sensor 11a, the sway information detection calculation function 23 and the sway suppression control function 24 can acquire information regarding sway such as the sway angle of the rope 7 and generate a speed control pattern so as to suppress the sway. Therefore, even when moving the container 2 or the like with the rope 7 extended for a long time, or horizontally moving the container 2 while winding up the long rope 7, the sway of the container 2 or the like can be suppressed, so that the container 2 or the like can be prevented from colliding with an obstacle.

[0047] Conventionally, when a skilled operator notices the occurrence of the sway of the rope 7, there are cases where the horizontal movement speed can be adjusted to suppress the sway and continue the horizontal movement of the container 2, but it is not easy to master such skills. In the container crane control device 100 according to this embodiment, even an unskilled operator can suppress the sway of the container 2, prevent a collision with an obstacle, and safely and reliably perform the horizontal movement of the container.

[0048] (Second Embodiment) FIG. 4 is a schematic block diagram illustrating a container crane control device according to the second embodiment. As shown in FIG. 4, in the container crane control device 200 according to the present embodiment, the main control device 216 has a swing information detection and calculation function 223. The swing information detection and calculation function 223 has a configuration different from that of the swing information detection and calculation function 23 of the container crane control device 100 according to the first embodiment. In the container crane control device 200 according to the present embodiment, the collision prevention device 202 has a collision prevention logic calculation function 219. The collision prevention logic calculation function 219 has a configuration different from that of the collision prevention logic calculation function 19 of the container crane control device 100 according to the first embodiment. The main control device 216 of the container crane control device 200 according to the present embodiment does not have a configuration corresponding to the swing suppression control function 24 of the container crane control device 100 according to the first embodiment. In other respects, the components of the container crane control device 200 according to the present embodiment are the same as those of the container crane control device 100 according to the first embodiment. The same components as those in the case of the first embodiment are denoted by the same reference numerals, and detailed descriptions thereof are appropriately omitted.

[0049] Based on the swing amplitude of the rope 7 output by the swing amplitude detection sensor 11a, the swing information detection and calculation function 223 calculates the swing angle of the rope 7. The swing information detection and calculation function 223 previously has an upper limit value of the swing angle of the rope 7 as a threshold value (first threshold value). When the calculated swing angle of the rope 7 exceeds the threshold value, the swing information detection and calculation function 223 outputs information regarding swing angle detection to the collision prevention logic calculation function 219.

[0050] Similar to the case of the collision prevention logic calculation function 19 of the first embodiment, the collision prevention logic calculation function 219 outputs a deceleration command when the obstacle distance becomes less than or equal to the deceleration stop distance. In addition, when the collision prevention logic calculation function 219 receives information regarding swing angle detection from the swing information detection and calculation function 223, it outputs an alarm transmission command for transmitting an alarm when the obstacle distance of the container 2 becomes less than or equal to the distance obtained by adding α to the deceleration stop distance. α is a positive constant having a dimension of distance and is, for example, set in advance in the collision prevention logic calculation function 219. The alarm transmission command is output to the alarm device 14.

[0051] The warning device 14 is installed, for example, in the driver's cab 9 where the operator 12 is present. When the warning transmission command is received, the warning device 14 transmits a warning to inform the operator 12 that the container 2 moving in the horizontal direction has a vibration exceeding the threshold value. The warning transmitted by the warning device 14 is, for example, the sounding of a preset warning sound, a warning voice, the lighting or flashing of a warning lamp, etc.

[0052] The collision prevention logic calculation function 219 may have multiple levels of constants regarding the relationship between the obstacle distance and the deceleration stop distance. For example, α1 = 2 and α2 = 1.5 are preset. When the obstacle distance becomes less than or equal to the deceleration stop distance + α1 (= 2), the collision prevention logic calculation function 219 outputs a first-stage first warning transmission command. When the obstacle distance becomes less than or equal to the deceleration stop distance + α2 (= 1.5), the collision prevention logic calculation function 219 outputs a second-stage second warning transmission command.

[0053] When the warning device 14 receives the first warning transmission command, it lights the yellow warning lamp, and when it receives the second warning transmission command, it blinks the red lamp. Thus, the operator 12 can subjectively grasp the degree of the risk of collision.

[0054] The vibration information detection calculation function 223 may have multiple threshold values regarding the vibration angle. In that case, the collision prevention logic calculation function 219 has multiple constants corresponding to each of the multiple threshold values regarding the vibration angle. The collision prevention logic calculation function 219 applies one of the multiple constants according to multiple pieces of information indicating that the vibration angle has exceeded the multiple threshold values of the vibration information detection calculation function 223.

[0055] For example, the swing information detection arithmetic function 223 has threshold values θ1th and θ2th for the swing angle, where θ1th < θ2th. When the swing information detection arithmetic function 223 outputs information indicating that the swing angle has exceeded θ1th to the collision prevention logic arithmetic function 219, the collision prevention logic arithmetic function 219 outputs an alarm transmission command for transmitting an alarm when the obstacle distance becomes less than or equal to the deceleration stop distance + α3. For example, α3 = 1.5. When the swing information detection arithmetic function 223 outputs information indicating that the swing angle has exceeded θ2th to the collision prevention logic arithmetic function 219, the collision prevention logic arithmetic function 219 outputs an alarm transmission command for transmitting an alarm when the obstacle distance becomes less than or equal to the deceleration stop distance + α4. For example, α = 2. That is, when the swing of the container 2 is large, even if the moving distance of the container 2 is shorter than the deceleration stop distance, the collision prevention logic arithmetic function 219 outputs an alarm transmission command.

[0056] FIG. 5 is an example of a flowchart for explaining the operation of the container crane control device according to the second embodiment. As shown in FIG. 5, in step S41, the obstacle distance arithmetic function 17 sequentially calculates the obstacle distance, which is the distance from the position of the tip of the container 2 to the position of the obstacle, based on the information regarding the profile of the obstacle output by the profile detection sensor 11. The obstacle distance arithmetic function 17 outputs the calculated obstacle distance to the collision prevention logic arithmetic function 219.

[0057] In step S42, the swing width detection sensor 11a detects the swing width of the rope 7 and outputs the detection result to the swing information detection arithmetic function 223. The swing information detection arithmetic function 223 calculates the swing angle of the rope 7 based on the swing width of the rope 7.

[0058] In step S43, the swing information detection arithmetic function 223 compares the calculated swing angle with a preset threshold value. When the swing information detection arithmetic function 223 determines that the swing angle exceeds the threshold value, it transfers the process to the next step S44. When the swing angle does not exceed the threshold value, it returns the process to step S42 and repeats the above operation.

[0059] In step S44, the swing information detection arithmetic function 223 outputs information regarding swing angle detection to the collision prevention logic arithmetic function 219 of the collision prevention device 102.

[0060] In step S45, the collision prevention logic arithmetic function 219 receives the information regarding swing angle detection and determines that the swing angle of the container 2 has exceeded a predetermined threshold value. The collision prevention logic arithmetic function 219 compares the obstacle distance with the distance obtained by adding a constant α to the deceleration stop distance. When the obstacle distance is less than or equal to "deceleration stop distance + α", the collision prevention logic arithmetic function 219 transfers the process to the next step S46. When the obstacle distance is longer than "deceleration stop distance + α", it waits as it is.

[0061] In step S46, the collision prevention logic arithmetic function 219 outputs an alarm reporting command to the alarm device 14. The alarm device 14 issues a predetermined alarm based on the alarm reporting command.

[0062] Thereby, the operator 12 can recognize that the moving container 2 is swinging and approaching an obstacle. The operator 12 can, for example, once stop the movement of the container 2, suppress the swing, and then start the movement of the container 2 again to prevent an unexpected accident due to the swing of the container 2.

[0063] The effects of the container crane control device 200 according to the present embodiment will be described. In the container crane control device 200 according to this embodiment, the swing information detection and calculation function 223 of the main control device 216 has a threshold value regarding the swing angle of the container 2. When the swing angle exceeds a predetermined threshold value, the swing information detection and calculation function 223 outputs information regarding swing angle detection. Further, when the obstacle distance becomes equal to or less than "deceleration stop distance + α (α > 0)", the collision prevention logic calculation function 219 of the collision prevention device 102 outputs an alarm transmission command. The alarm device 14 that has received the alarm transmission command issues an alarm notifying the operator in the cab 9 that the container 2 is swinging and approaching an obstacle. Therefore, the operator 12 can reduce the horizontal movement speed of the container 2 or perform an operation to suppress the swing of the container 2, thereby preventing an unexpected accident such as the container 2 colliding with an obstacle.

[0064] As described above, in this embodiment, even when the main control device 216 does not implement a swing suppression control function for generating a speed control pattern for swing suppression, it is possible to prevent the container from colliding due to swing. When the storage capacity of the program of the PLC constituting the main control device is insufficient, etc., it may not be possible to newly add a swing suppression control function to the main control device. Even in such a case, in the container crane control device 200 according to this embodiment, the swing of the container 2 can be detected and the operator 12 can be made aware that the container 2 is approaching an obstacle. By the operator 12 taking appropriate measures, it becomes possible to prevent an unexpected accident. On the other hand, by implementing the swing suppression control function 24 in the case of the first embodiment, it is possible to more reliably prevent the container from colliding with an obstacle.

[0065] (Third Embodiment) FIG. 6 is a schematic block diagram illustrating a container crane control device according to the third embodiment. As shown in FIG. 6, in the container crane control device 300 according to the present embodiment, the collision prevention device 302 has a collision prevention logic calculation function 319. The collision prevention logic calculation function 319 has a configuration different from that of the collision prevention logic calculation function 19 of the container crane control device 100 according to the first embodiment. The container crane control device 300 according to the present embodiment is different from the container crane control device 100 according to the first embodiment in that the main control device 316 has a horizontal movement interlock 25. In other respects, the components of the container crane control device 300 according to the present embodiment are the same as those of the container crane control device 100 according to the first embodiment, and the same components are denoted by the same reference numerals and detailed descriptions are appropriately omitted.

[0066] Similar to the case of the collision prevention logic calculation function 19 of the first embodiment, the collision prevention logic calculation function 319 generates a deceleration command when the horizontal obstacle distance of the container 2 becomes less than or equal to the deceleration stop distance. In addition, the collision prevention logic calculation function 319 has a function of comparing the height of the lower surface of the container 2 with the maximum height among the profiles of the obstacles. In the initial state before starting the horizontal movement and the vertical movement, the horizontal movement of the container 2 is interlocked. When the height of the lower surface of the container 2 exceeds the maximum height of the obstacle, the collision prevention logic calculation function 319 outputs a command to release the horizontal movement interlock to the horizontal movement interlock 25.

[0067] When the horizontal movement interlock (interlock function) 25 of the main control device 316 receives the interlock release command output from the collision prevention logic calculation function 319, it acts to supply the output of the speed reference calculation function 20 to the speed deceleration control function 21.

[0068] FIG. 7 is an example of a flowchart for explaining the operation of the container crane control device according to the third embodiment. As shown in FIG. 7, in step S51, the profile detection sensor 11 sequentially calculates the height of the lower surface of the container 2 and outputs it to the collision prevention logic arithmetic function 319. Note that, instead of the output value of the profile detection sensor 11, the data of the length of the rope 7 may be used for the calculation of the height of the lower surface of the container 2.

[0069] In step S52, the profile detection sensor 11 detects the profile of the obstacle and outputs it to the obstacle distance arithmetic function 17. The obstacle distance arithmetic function 17 calculates the height of the obstacle at each position, extracts the maximum height value, and outputs it to the collision prevention logic arithmetic function 319. In the example of FIG. 1, the maximum height is the height HA at the position PA, the value of the height HA is output to the collision prevention logic arithmetic function 319, and the collision prevention logic arithmetic function 319 stores the value of the height HA.

[0070] Note that, in the initial state before the collision prevention logic arithmetic function 319 executes the height determination, the output of the speed reference arithmetic function 20 is interlocked. Therefore, even if the operator 12 operates the main controller 13 to move the container 2 in the horizontal direction, 0 is input as the speed reference to the speed deceleration control function 21.

[0071] In step S53, the collision prevention logic arithmetic function 319 compares the stored maximum height of the obstacle with the height of the lower surface of the container 2. When the collision prevention logic arithmetic function 319 determines that the height of the lower surface of the container 2 is higher than the maximum height of the obstacle, the process proceeds to the next step S54. When the collision prevention logic arithmetic function 319 determines that the height of the lower surface of the container 2 is less than or equal to the maximum height of the obstacle, the process returns to step S51 and the above-described process is repeated.

[0072] In step S54, the collision prevention logic arithmetic function 319 outputs an interlock release command to the horizontal movement interlock 25.

[0073] The horizontal movement interlock 25 acts to supply the speed reference output by the speed reference calculation function 20 to the speed deceleration control function based on the interlock release command. The speed deceleration control function 21 applies a predetermined acceleration rate to the speed reference output from the speed reference calculation function 20 and outputs it to the motor drive control function 22.

[0074] In step S55, the operator 12 starts the horizontal movement of the container 2 while maintaining the height of the container 2.

[0075] The effects of the container crane control device 300 according to this embodiment will be described. In the container crane control device 300 according to this embodiment, the main control device 316 interlocks the horizontal movement of the container 2 until the collision prevention logic calculation function 319 executes a determination regarding the height of the lower surface of the container 2. The collision prevention logic calculation function 319 determines that the height of the lower surface of the container 2 exceeds the maximum height of the obstacle and releases the interlock. Therefore, when moving horizontally, since there are no horizontal obstacles, there is no need to consider the swing generated by the deceleration operation.

[0076] In the container crane control device 300 according to this embodiment, swing suppression is not required, and even if the operator accidentally swings the load or exceeds the placement target position, the container will not collide with an obstacle.

[0077] (Fourth Embodiment) FIG. 8 is a schematic block diagram illustrating a container crane control device according to the fourth embodiment. As shown in FIG. 8, in the container crane control device 400 according to the present embodiment, the collision prevention device 402 has a collision prevention logic calculation function 419. The collision prevention logic calculation function 419 has a configuration different from that of the collision prevention logic calculation function 319 of the container crane control device 300 according to the third embodiment. In other respects, the components of the container crane control device 400 according to the present embodiment are the same as those of the container crane control device 300 according to the third embodiment, and the same reference numerals are assigned to the same components, and detailed descriptions thereof are appropriately omitted.

[0078] The collision prevention logic calculation function 419 outputs an interlock release command to the horizontal movement interlock 25 before the lower surface of the container 2 exceeds the maximum height of the obstacle. Thereby, it is possible to reach the moving position of the target container earlier.

[0079] FIG. 9 is an example of a flowchart for explaining the operation of the container crane collision prevention control device according to the fourth embodiment. As shown in FIG. 9, in step S61, similar to the case of the third embodiment, the profile detection sensor 11 calculates the height of the lower surface of the container 2 and outputs it to the collision prevention logic calculation function 419.

[0080] In the initial state before the collision prevention logic calculation function 419 executes the determination regarding the height of the lower surface of the container 2, the output of the speed reference calculation function 20 is interlocked. Therefore, in step S62, the collision prevention logic calculation function 419 calculates the horizontal movement time (first time), which is the time until reaching the obstacle when the container 2 moves horizontally at the maximum speed and a predetermined acceleration / deceleration rate, and stores the result.

[0081] In step S63, the profile detection sensor 11 detects the profile of the obstacle and outputs it to the obstacle distance calculation function 17. Similar to the case of the third embodiment, the obstacle distance calculation function 17 calculates the height of the obstacle at each position and outputs the data of the maximum height to the collision prevention logic calculation function 419. The collision prevention logic calculation function 419 stores the data of the maximum height of the obstacle.

[0082] In step S64, the collision prevention logic calculation function 419 calculates the deceleration stop distance in the case of the vertical movement of the container 2 based on the maximum height of the obstacle. The deceleration stop distance in the case of vertical movement is calculated using the preset deceleration rate for vertical movement, similar to the case of horizontal movement. That is, in the case of vertical movement, the deceleration stop distance in the vertically upward direction from the timing when the deceleration command is output based on the speed reference at that time until stopping is calculated. The collision prevention logic calculation function 419 stores the value obtained by subtracting the deceleration stop distance in the vertical direction from the maximum height of the obstacle.

[0083] In step S65, the collision prevention logic calculation function 419 compares the height of the lower surface of the container 2 with "the maximum height of the obstacle - the deceleration stop distance in the vertically upward direction". When the collision prevention logic calculation function 419 determines that the height of the lower surface of the container 2 is equal to or greater than "the maximum height of the obstacle - the deceleration stop distance in the vertically upward direction", the process is transferred to the next step S66. When the collision prevention logic calculation function 419 determines that the height of the lower surface of the container 2 is lower than "the maximum height of the obstacle - the deceleration stop distance in the vertically upward direction", the process returns to step S61 and the above-described operations are repeated.

[0084] In step S66, the collision prevention logic calculation function 419 calculates and stores the vertical upward deceleration time (second time), which is the time when the container 2 stops at the deceleration rate obtained by calculating the deceleration stop distance in the vertically upward direction. The collision prevention logic calculation function 419 compares the stored horizontal movement time with the vertical upward deceleration time. When the collision prevention logic calculation function 419 determines that the vertical upward deceleration time is less than or equal to the horizontal movement time, it causes the process to transition to the next step S67. When the collision prevention logic calculation function 419 determines that the vertical upward deceleration time is longer than the horizontal movement time, it returns the process to step S61 and repeats the above-described operation.

[0085] In step S67, the collision prevention logic calculation function 419 outputs an interlock release command for releasing the interlock of the horizontal movement to the main control device 316.

[0086] In step S68, the operator 12 starts the horizontal movement of the container 2.

[0087] The effects of the container crane control device 400 according to this embodiment will be described. In the container crane control device 400 according to this embodiment, even before the height of the container 2 in the vertical direction reaches the maximum height of the obstacle, during the period of decelerated travel at the deceleration rate of the vertical movement, the collision prevention logic calculation function 419 enables the horizontal movement on the condition that even when moving at the maximum speed in the horizontal direction, it will not reach the obstacle before that. Therefore, until the lower surface of the container 2 reaches the maximum height, the actual movement time of the container 2 can be shortened compared to the case where the horizontal movement is prohibited, and productivity can be improved. When calculating the horizontal movement time, in order to obtain the shortest time, it is preferable to move at the maximum speed as described above. Needless to say, if the horizontal speed after the interlock release is a predetermined value, it does not have to be the maximum speed.

[0088] (Fifth Embodiment) FIG. 10 is a schematic block diagram illustrating a container crane control device according to a fifth embodiment. As shown in FIG. 10, a container crane control device 500 according to this embodiment includes a collision prevention device 502 having an obstacle distance calculation function 517 and a collision prevention logic calculation function 519. The obstacle distance calculation function 517 has a configuration different from that of the obstacle distance calculation function 17 of the container crane control device 300 according to the first embodiment. The collision prevention logic calculation function 519 has a configuration different from that of the collision prevention logic calculation functions 319 and 419 of the container crane control devices 300 and 400 according to the third and fourth embodiments. In other respects, the components of the container crane control device 500 according to this embodiment are the same as those of the container crane control devices according to the other embodiments described above. The same components are denoted by the same reference numerals, and detailed descriptions thereof are appropriately omitted.

[0089] The obstacle distance calculation function 517 sequentially calculates the obstacle distance using the profile of the obstacle supplied from the profile detection sensor 11 and outputs it to the collision prevention logic calculation function 519. The obstacle distance calculation function 517 is connected to a container loading position input device 15a. The container loading position input device 15a is, for example, a touch panel type input device installed in the driver's cab 9, and an image of the contour of the stack of the placed containers 3 is displayed. The operator 12 inputs information on the position where the container 2 will be moved and loaded by selecting any one of the contours of the stack of the placed containers 3 displayed on the container loading position input device 15a. The container loading position input device 15a outputs the input information on the planned loading position of the container 2 to the obstacle distance calculation function 517.

[0090] Based on the input information on the planned loading position, the obstacle distance calculation function 517 calculates the maximum height of the obstacle in front of the loading position. The obstacle distance calculation function 517 outputs the obstacle distance to the obstacle having the maximum height in front of the planned loading position and the height of the obstacle to the collision prevention logic calculation function 519.

[0091] When the conflict prevention logic arithmetic function 519 determines that the height of the lower surface of the container 2 exceeds the height of the obstacle having the maximum height before the planned loading position, the interlock release command for releasing the prohibition of the horizontal movement of the container 2 is output to the horizontal movement interlock 25.

[0092] FIG. 11 is an example of a flowchart for explaining the operation of the container crane collision prevention control device according to the fifth embodiment. The operation of the container crane control device 500 according to the present embodiment will be described using a flowchart. As shown in FIG. 11, in step S71, the operator 12 inputs the planned loading position of the container 2 by the container loading position input device 15a.

[0093] In step S72, the deceleration distance-time arithmetic function for the vertical movement of the container 2 integrates the vertical movement speed of the container 2, calculates the height of the lower surface of the container 2, and outputs it to the collision prevention logic arithmetic function 519.

[0094] In step S73, the obstacle distance arithmetic function 517 calculates the maximum height of the obstacle in front of the planned loading position using the input planned loading position of the container 2. In the example of FIG. 1, when attempting to load the container 2 at the position PC, the obstacle distance arithmetic function 517 outputs the height HA at the position PA to the collision prevention logic arithmetic function 519. The collision prevention logic arithmetic function 519 stores the height HA. When attempting to load the container 2 at the position PD, the obstacle distance arithmetic function 517 outputs the height at the position PB to the collision prevention logic arithmetic function 519. The collision prevention logic arithmetic function 519 stores the height HB.

[0095] In step S74, the collision prevention logic arithmetic function 519 compares the maximum height of the obstacle with the height of the lower surface of the container 2. When the height of the lower surface of the container 2 is higher than the maximum height of the obstacle, the collision prevention logic arithmetic function 519 outputs an unlocking command for releasing the prohibition of the horizontal movement of the container 2 to the horizontal movement interlock 25. In step S75, the horizontal movement interlock 25 acts to output the speed reference output by the speed reference arithmetic function 20 to the speed deceleration control function 21.

[0096] In step S76, the operator starts the horizontal movement of the container 2 while maintaining the height of the container 2.

[0097] The effects of the container crane control device 500 according to this embodiment will be described. In the container crane control device 500 according to this embodiment, the loading planned position is specified by the container loading position input device 15a, and the maximum height of the obstacle in front of the loading planned position can be detected by the obstacle distance arithmetic function 517 and the collision prevention logic arithmetic function 519. Therefore, since it is only necessary to perform vertical movement according to the loading planned position, the time required for vertical movement can be shortened, which can contribute to the improvement of productivity.

[0098] In the above description, the container 2 is vertically moved and then horizontally moved while being suspended by the spreader 1. However, the present invention is not limited to this, and the moving operation may be performed without suspending the container 2 by the spreader. In that case, since the spreader 1 is suspended by the rope 7, the reference position for horizontal movement is the tip in the traveling direction of the spreader 1, and the height is the height to the lower surface of the spreader 1. The heights of the spreader 1 and the container 2 are given, and the container crane control device can calculate the heights of the lower surfaces of the spreader 1 and the container 2 by measuring the heights of the tips of the spreader 1 and the container 2.

[0099] Each of the above-described embodiments can be applied in combination with each other. For example, the collision prevention logic calculation function 219 and the swing information detection calculation function 223 in the case of the second embodiment can be applied to the container crane control device 100 according to the first embodiment. Further, as shown in FIGS. 6, 8, and 10, in the container crane control devices 300, 400, 500 according to the third to fifth embodiments, the collision prevention logic calculation functions 19, 219, the swing information detection calculation functions 23, 223, and the swing suppression control function 24 in the cases of the first and second embodiments can be applied. Furthermore, the components of the third to fifth embodiments can be applied to each other, and the collision prevention logic calculation function 419 in the case of the fourth embodiment can be applied to the container crane control device 500 according to the fifth embodiment to move the container 2 more quickly.

[0100] In this way, a container crane control device that can easily avoid collisions between containers can be realized.

[0101] Although some embodiments of the present invention have been described, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and its equivalent scope.

Description of Reference Numerals

[0102] 1... spreader, 2... container, 3... container placement, 4... container ship, 7... rope, 8... trolley, 9... driver's cab, 10... electrical room, 11... profile detection sensor, 11a... amplitude sensor, 12... operator, 13... main controller, 14... alarm device, 15... display device, 15a... container loading position input device, 16, 216, 316... main control device, 17, 517... obstacle distance calculation function, 18... deceleration distance-time calculation function, 19, 219, 319, 419, 519... collision prevention logic calculation function, 20... speed reference calculation function, 21... speed deceleration control function, 22... motor drive control function, 23, 223... swing information detection calculation function, 24... swing suppression control function, 25... horizontal movement interlock, 100, 200, 300, 400, 500... container crane control device, 102, 202, 302, 402, 502... collision prevention device

Claims

【Claim 1】 Vibration information calculation means that outputs from an amplitude sensor and calculates the swing angle of the rope based on the swing amplitude of the rope suspending the cargo; Speed reference calculation means that sequentially calculates and outputs a first speed reference for the horizontal movement of the cargo based on the operation of an operator; When the first speed reference output from the speed reference calculation means or a deceleration command to start decelerating the cargo is input, based on the swing angle, the second speed reference for the horizontal movement of the cargo is sequentially output to a motor drive device that drives a motor for horizontally moving the cargo so as to reduce the swing of the rope and to configure a preset speed control pattern; speed control means; A main control device including: Obstacle detection means for detecting an obstacle existing in the direction in which the cargo travels; Obstacle distance calculation means for sequentially calculating and outputting an obstacle distance that is the horizontal distance between the cargo and the obstacle; Deceleration stop distance calculation means for sequentially calculating and outputting a deceleration stop distance from the start of deceleration to the stop of the horizontal movement of the cargo based on the first speed reference and the second speed reference; Collision prevention logic calculation means for generating the deceleration command based on the obstacle distance and the deceleration stop distance and outputting it to the speed control means; A collision prevention device including: Equipped with: When the swing angle exceeds a first threshold value, the swing information calculation means outputs information regarding swing angle detection to the collision prevention logic calculation means; The collision prevention logic calculation means, when receiving the information regarding swing angle detection from the swing information calculation means and when the difference between the obstacle distance and the deceleration stop distance becomes equal to or less than a predetermined range, outputs an alarm reporting command for notifying the operator that the rope is swinging and the cargo is approaching the obstacle. A container crane control device.

Images