Overhead crane monitoring system

Abstract

To provide an image suitable for remotely controlling an overhead crane to an operator.SOLUTION: An overhead crane monitoring system monitors an overhead crane 1 which includes a traveling body 2 traveling along a rail 4, a traversing truck 3 traveling in a direction orthogonal to the traveling direction of the traveling body 2 along the traveling body 2, and a hoisting device 5 mounted on the traversing truck 3. A panoramic camera 6 for performing photographing in a looking down posture is installed on one end part of the traveling body 2. An image photographed by the panoramic camera 6 is displayed on a wide display 21 installed in a remote operation room.SELECTED DRAWING: Figure 3

Description

TECHNICAL FIELD

[0001] The present invention relates to an overhead crane monitoring system. BACKGROUND ART

[0002] Overhead cranes are installed in material storage yards and the like. For the practical implementation of remote operation of overhead cranes, it is required to construct an overhead crane monitoring system that allows the overhead crane and the surroundings of the overhead crane to be monitored from a remote operation room. Patent Document 1 discloses an overhead crane operation apparatus configured to be provided with a video camera that captures the working state of the overhead crane. Patent Document 2 discloses an operation method for container cranes, transfer cranes, unloaders and the like, in which a camera mounted on a trolley captures images of a load to be placed and a suspended load, the video is transmitted to a display device provided on the ground, and an operator performs a lifting operation for the load to be placed or a landing operation for the suspended load from an operation panel provided on or near the ground based on the video displayed on the display device. PRIOR ART DOCUMENTS PATENT DOCUMENTS

[0003] PATENT DOCUMENT 1 Japanese Unexamined Patent Application Publication No. 2002-274779 PATENT DOCUMENT 2 Japanese Unexamined Patent Application Publication No. 5-246683 SUMMARY OF INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0004] In Patent Document 1, the overhead crane is imaged by a camera installed on the ground, but for the practical implementation of remote operation of the overhead crane, it is necessary to grasp the entry of persons into the ground area and the state of materials and equipment, and video from the line of sight of the driver's cab on the overhead crane (on the machine) is required. Furthermore, in Patent Document 2, the images of the placed and suspended loads are captured by three cameras attached to the trolley. However, the operator viewing these images must mentally combine the images captured from multiple different angles, which can place a heavy burden on the operator and potentially impair their ability to make quick decisions.

[0005] This invention has been made in view of the above-mentioned points, and aims to provide operators with video footage suitable for remotely controlling overhead cranes. [Means for solving the problem]

[0006] The present invention relates to an overhead crane monitoring system for monitoring an overhead crane comprising a traveling body that travels along rails, a traversing carriage that travels along the traveling body in a direction perpendicular to the direction of travel of the traveling body, and a hoisting device mounted on the traversing carriage, wherein a panoramic camera that takes pictures in an overhead position is installed at one end of the traveling body, and the image captured by the panoramic camera includes: Even when the position of the traveling body in the direction of travel changes, The image is characterized by showing the storage area below the overhead crane, a virtual vertical plane perpendicular to the traverse direction which is the direction of travel of the traverse trolley at the end face position of the other end of the traveling body, virtual vertical planes perpendicular to the direction of travel at both ends of the travel direction, and the traveling body. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide an operator with video footage suitable for remotely controlling an overhead crane. [Brief explanation of the drawing]

[0008] [Figure 1] This diagram shows the schematic configuration of an overhead crane. [Figure 2] This diagram shows the schematic configuration of an overhead crane. [Figure 3] This is a diagram showing an example of the configuration of a vehicle. [Figure 4] This diagram schematically illustrates the image captured by a panoramic camera. [Figure 5] This figure shows an example of a network configuration for an overhead crane monitoring system. [Figure 6] This figure shows an example of a surveillance image. [Modes for carrying out the invention]

[0009] Preferred embodiments of the present invention will be described below with reference to the attached drawings. Figures 1 and 2 show the schematic configuration of the overhead crane 1. Figure 1 is a schematic plan view of the overhead crane 1, and Figure 2 is a schematic perspective view of the overhead crane 1. The overhead crane 1 is installed over a storage area 7 inside the building and lifts and transports materials placed in the storage area 7. The overhead crane 1 comprises a pair of rails 4 installed in the building, a traveling body 2 that travels along the rails 4, a traversing carriage 3 that travels along the traveling body 2, and a hoisting device 5 mounted on the traversing carriage 3. The traversing carriage 3 travels in a direction perpendicular to the direction of travel of the traveling body 2. The hoisting device 5 hoists up and down lifting devices 5a such as hooks to suspend loads (materials) placed in the storage area 7. In this application, the direction of travel (the direction in which the rails 4 extend) is defined as the x-direction, the traversing direction which is the direction in which the traversing carriage 3 travels is defined as the y-direction, and the height direction is defined as the z-direction.

[0010] Figure 3 shows an example of the configuration of the running body 2. Figure 3(a) is a front view of the running body 2 (the transverse bogie 3 is omitted), and (b) is a top view of the running body 2. The traveling body 2 is what is called a crane girder, and is a long member extending in the y-direction, with saddles 2c at both ends supported by rails 4. As shown in Figure 3(a), a panoramic camera 6 is installed on the lower part of one end 2a of the vehicle 2. The panoramic camera 6 is positioned so that its shooting direction is downward, as indicated by arrow A, for example, as if a person were looking down at a suspended load from the driver's cab on the vehicle, and it takes pictures in an overhead view. The panoramic camera 6 has a horizontal field of view of 180° and is positioned on one end 2a of the vehicle 2 so that the horizontal field of view is centered in the lateral direction (y direction).

[0011] Here, with reference to Figure 4, the image captured by the panoramic camera 6 will be explained. Figure 4 is a schematic diagram showing the image captured by the panoramic camera 6. As shown in Figure 4, the image captured by the panoramic camera 6 shows the storage area (building floor) 7 below the overhead crane 1. The image captured by the panoramic camera 6 also shows the wall 8 and rails 4 on the other end 2b side of the traveling body 2. The image captured by the panoramic camera 6 also shows both walls 9 and 10 in the direction of travel (x direction). Furthermore, the image captured by the panoramic camera 6 shows the traveling body 2 on which the panoramic camera 6 is installed, extending in the direction of the background. When the traveling position of the traveling body 2 changes, the image captured by the panoramic camera 6 also changes, but what is captured remains the same as described above.

[0012] In addition to the panoramic camera 6, other cameras may be installed on the vehicle 2, the traversing trolley 3, or on the ground. In this embodiment, as shown in Figure 3(b), camera 11 is installed on the traversing trolley 3 to photograph the lifting device 5a and the suspended load.

[0013] Furthermore, as shown in Figures 1 and 3(b), a laser rangefinder 12 is installed on the vehicle 2, and a reflector 13 is installed near the end of the rail 4 so as to face the laser rangefinder 12. The vehicle's position can be measured using the laser rangefinder 12 and the reflector 13. In this embodiment, the laser rangefinder 12 and the reflector 13 function as vehicle position measurement means as defined in the present invention. In addition to the laser rangefinder, other means such as IR cables or IC tags may also be used to constitute the vehicle position measurement means.

[0014] Further, as shown in Fig. 3(b), a laser rangefinder 14 is installed on the traveling body 2, and a reflection plate 15 is installed on the traversing trolley 3 so as to face the laser rangefinder 14. The traversing position of the traversing trolley 3 can be measured by the laser rangefinder 14 and the reflection plate 15. In the present embodiment, the laser rangefinder 14 and the reflection plate 15 function as the traversing position measuring means referred to in the present invention. In addition to the laser rangefinder, the traversing position measuring means may be configured using, for example, an IR cable, an IC tag, or the like.

[0015] Further, as shown in Fig. 3(b), in the hoisting device 5, a rotation detector 16 is installed on one of the portions that rotate relative to each other during hoisting or lowering of the lifting attachment 5a, and a reflection mark 17 is installed on the other. The height position of the lifting attachment 5a by the hoisting device 5 can be measured by the rotation detector 16 and the reflection mark 17. In the present embodiment, the rotation detector 16 and the reflection mark 17 function as the height position measuring means referred to in the present invention. In addition to the rotation detector, the height position measuring means may be configured using, for example, a pulse generator or the like.

[0016] Fig. 5 shows an example of the network configuration of the overhead crane monitoring system. As described above, the panoramic camera 6 is installed on the overhead crane 1. The panoramic camera 6 performs wireless communication with the components on the remote control room side via the hub 29 and the communication device 30. Further, the camera 11 is installed on the overhead crane 1. The camera 11 performs wireless communication with the components on the remote control room side via the encoder 20, the hub 29 and the communication device 30. Further, the overhead crane 1 is provided with a laser rangefinder 12 and a reflection plate 13 functioning as traveling position measuring means, a laser rangefinder 14 and a reflection plate 15 functioning as traversing position measuring means, and a rotation detector 16 and a reflection mark 17 functioning as height position measuring means. The laser rangefinder 12, the laser rangefinder 14, and the rotation detector 16 perform wireless communication with the components on the remote control room side via a PLC (Programmable Logic Controller) 18, the hub 29 and the communication device 30.

[0017] Meanwhile, a display 21 is installed in the remote control room to show images captured by the panoramic camera 6. A wide display, such as an ultrawide monitor, is used as the display 21 for showing images captured by the panoramic camera 6. The display 21 communicates wirelessly with the components on the overhead crane 1 side via a decoder 26, a hub 31, and a communication device 32. Furthermore, a display 22 is installed in the remote control room to show the video captured by camera 11. The display 22 communicates wirelessly with the components on the overhead crane 1 side via decoder 25, hub 31, and communication device 32. Furthermore, a display 23 is installed in the remote control room to show information such as the travel position of the mobile body 2, the traverse position of the traverse trolley 3, and the height position of the lifting device 5a. The display 23 communicates wirelessly with the components on the overhead crane 1 side via a computer 27, a hub 31, and a communication device 32. Furthermore, the remote control room is equipped with control devices 24, such as pendant switches, for remote operation. The control devices 24 communicate wirelessly with the components on the overhead crane 1 side via a PLC 28, a hub 31, and a communication device 32. On the overhead crane 1 side, which is the actual site, there are existing control devices (not shown), such as pendant switches. For example, if the wireless connection is interrupted due to a PLC healthy check, the crane operation is stopped and the system automatically switches to operation using the existing control devices on site.

[0018] Note that the network configuration shown in Figure 5 is just one example, and other cameras may be installed. When using multiple cameras, it is preferable to install a display for each camera in the remote control room. Alternatively, a speaker may be installed on the overhead crane 1, allowing for public address broadcasts from a microphone installed in the remote control room. This would enable alerts and other announcements to be made to on-site workers. Alternatively, a sound-collecting microphone may be installed on the overhead crane 1, and the sound may be played back through a speaker installed in the remote control room. This would allow the remote control room to monitor the situation at the site.

[0019] Now, with reference to Figure 6, an example of what is displayed on the display 23 will be explained. Figure 6 is a diagram showing an example of a monitoring image 60 to be displayed on the display 23. As shown in Figure 6, the display 23 displays a monitoring image 60 under the control of a computer 27, which functions as a display control means. The monitoring image 60 has a display area 61 in the center that displays the driving position and traverse position. To the left of the display area 61 is a display area 62 that displays the main circuit status, and to the right is a display area 63 that displays the height position.

[0020] The main power supply status indicator unit 64 displays the ON / OFF status of the main power supply. For example, the main power supply status indicator unit 64 lights up when it is ON and turns off when it is OFF. The operation location status indicator 65 displays the status of the operation location selector switch. The operation location status indicator 65 lights up when the operation location is on the ground and turns off when the operation location is on the aircraft. The PLC communication status indicator 66 displays the communication status between the ground and the onboard PLC. The PLC communication status indicator 66, for example, is off when the communication status is normal and lights up when there is an abnormality.

[0021] In the display area 61, a map 67 schematically representing the layout of the building in a plan view is displayed, and a first display part 68 representing the mobile body 2 and a second display part 69 representing the traverse trolley 3 are displayed on the map 67. The vertical direction of the monitoring image 60 corresponds to the travel direction (x direction), and the horizontal direction corresponds to the traverse direction (y direction). Based on the travel position of the mobile body 2 and the traverse position of the traverse trolley 3 measured by the laser rangefinders 12, 14 and reflectors 13, 15, the display parts 68 and 69 move on the map 67. In this way, the travel position of the mobile body 2 and the traverse position of the traverse trolley 3 are displayed graphically.

[0022] A driving position display unit 70 is located to the left of map 67. The driving position display unit 70 displays the driving position of the vehicle 2 using numerical values ​​and indicators. The driving position of the vehicle 2 can be expressed as a distance from either end position in the direction of travel, for example. The driving position of the vehicle 2 is measured by a laser rangefinder 12 and a reflector 13, and the measured value is reflected in the driving position display unit 70. Below map 67, a traverse position display unit 71 is positioned. The traverse position display unit 71 displays the traverse position of the traverse trolley 3 using numerical values ​​and indicators. The traverse position of the traverse trolley 3 can be expressed as a distance from either end position in the traverse direction as the starting point. rampant The position is measured by the laser rangefinder 14 and the reflector 15, and the measured value is reflected in the horizontal position display unit 71. The dotted lines are virtual lines used to indicate the display areas that make up the driving position display unit 70 and the traverse position display unit 71, respectively, and are not displayed in the monitoring image 60.

[0023] In the display area 62, the main circuit current value display unit 72 displays the current value of the main circuit power supply of the overhead crane 1 using numerical values ​​and a meter display. The current value of the main circuit power supply is measured by an ammeter (not shown), and the measured value is reflected in the main circuit current value display unit 72. Furthermore, the main circuit voltage value display unit 73 displays the voltage value of the main circuit power supply of the overhead crane 1 using numerical values ​​and a meter display. The voltage value of the main circuit power supply is measured by a voltmeter (not shown), and the measured value is reflected in the main circuit voltage value display unit 73. Note that the dotted lines are virtual lines used to indicate the display areas that make up the main circuit current value display unit 72 and the main circuit voltage value display unit 73, respectively, and are not displayed in the monitoring image 60.

[0024] In the display area 63, the hook height display unit 74 displays the height position of the lifting device 5a using numerical values ​​and indicator displays. The height position of the lifting device 5a by the hoisting device 5 is measured by the rotation detector 16 and the reflective mark 17, and the measured value is reflected in the hook height display unit 74. Note that the dotted line is a virtual line indicating the display area that constitutes the hook height display unit 74, and is not displayed in the monitoring image 60. Furthermore, the load height display unit 75 displays the height of the base of the load from the ground using a numerical display. When button 76 is pressed after the load has been rigged and the ground clearance check is complete, the display on the load height display unit 75 is set. The numerical value displayed on the load height display unit 75 may be a value based on sensors, for example, or a value entered by the user. Furthermore, the suspended load display unit 77 displays the suspended load numerically. The numerical value displayed in the suspended load display unit 77 may be, for example, a value based on sensors, or a value entered by the user.

[0025] In this way, by quantifying and displaying the status of the overhead crane 1, the operator can accurately grasp the status of the overhead crane 1, enabling precise remote control such as inching. Furthermore, by graphically displaying the travel position of the traveling body 2 and the traverse position of the traverse carriage 3 using map 67 and display parts 68 and 69, the operator can visually and intuitively grasp the status of the overhead crane 1.

[0026] The overhead crane monitoring system described above can provide the operator with video footage suitable for remotely controlling the overhead crane 1. As shown in Figure 4, the video captured by the panoramic camera 6 is equivalent to the video from the driver's cab on board the aircraft. By providing this to the operator in the remote control room, the operator can monitor the status of the overhead crane 1, the presence of people on the ground, and the status of materials and equipment in a way that is close to what they would see with their own eyes from on board the aircraft, and monitor the overhead crane 1 and its surroundings.

[0027] Furthermore, by displaying the images captured by the panoramic camera 6 on a single wide display 21, seamless image display is possible. For example, if the images captured by the panoramic camera 6 were to be split and displayed on multiple displays, the operator would need to understand the relationships between overlapping areas of the images on each display, which could require extra processing time. In contrast, by displaying the images captured by the panoramic camera 6 on a single wide display 21, the operator does not need to understand the relationships between overlapping areas of the images on each display, thus reducing the burden on the operator.

[0028] In this way, a wide area can be viewed from the remote control room, allowing for accurate assessment of the status of the overhead crane 1, the presence of people on the ground, and the condition of materials and equipment. This ensures the same level of operability as operating from the onboard control room, making remote operation practical.

[0029] While a panoramic camera 6 with a horizontal field of view of 180° or more is preferable, one with a horizontal field of view of less than 180° is also acceptable. In this case, the image captured by the panoramic camera 6 may show only one of the walls 9 or 10 in the direction of travel (x direction), or neither may be shown. However, if this is sufficient, a panoramic camera 6 with a horizontal field of view of less than 180° is also acceptable.

[0030] Furthermore, as shown in Figure 6, the numerical values ​​of the travel position of the traveling body 2 measured by the laser rangefinders 12 and 14 and the reflectors 13 and 15, the numerical values ​​of the traverse position of the traverse trolley 3, and the numerical values ​​of the height position of the lifting device 5a measured by the rotation detector 16 and the reflective mark 17 may be displayed, for example, on a wide display 21, superimposed on the image captured by the panoramic camera 6.

[0031] Although the present invention has been described above along with its embodiments, these embodiments are merely examples of how the present invention can be implemented, and the technical scope of the present invention should not be interpreted as being limited by them. In other words, the present invention can be implemented in various forms without departing from its technical concept or its main features.

[0032] In the embodiment, an example was described in which the overhead crane 1 is installed indoors (inside a building), but the present invention is also applicable when the overhead crane 1 is installed outdoors. It was stated that the image captured by the panoramic camera 6 shows the wall 8 on the other end 2b side of the traveling body 2, but when the overhead crane 1 is installed outdoors, there is no wall. Therefore, the image captured by the panoramic camera 6 should be set as follows. That is, whether the overhead crane 1 is installed indoors or outdoors, the image captured by the panoramic camera 6 should be set so that the area below the overhead crane 1 (the floor if indoors, the ground if outdoors) and a virtual vertical plane 33 (the xz plane 33 shown in Figure 3(a)) perpendicular to the lateral direction (y direction) at the end face position of the other end 2b of the traveling body 2 are captured.

[0033] Similarly, it was stated that the images captured by the panoramic camera 6 show both walls 9 and 10 in the direction of travel (x direction). However, when the overhead crane 1 is installed outdoors, there are no walls. Therefore, it is preferable to set the images captured by the panoramic camera 6 as follows: In other words, whether the overhead crane 1 is installed indoors or outdoors, the images captured by the panoramic camera 6 should show a virtual vertical plane 34 (yz plane 34 shown in Figure 1) perpendicular to the direction of travel (x direction) at both ends of the direction of travel. [Explanation of symbols]

[0034] 1: Overhead crane, 2: Traveling body, 3: Traverse trolley, 4: Rails, 5: Hoisting device, 6: Panoramic camera, 7: Storage area, 12, 14: Laser rangefinder, 13, 15: Reflector, 16: Rotation detector, 17: Reflective mark, 21: Wide display, 23: Display, 27: Computer, 60: Monitoring image, 68: First display part, 69: Second display part

Claims

1. An overhead crane monitoring system for monitoring an overhead crane comprising a traveling body that travels along rails, a traversing carriage that travels along the traveling body in a direction perpendicular to the direction of travel of the traveling body, and a hoisting device mounted on the traversing carriage, A panoramic camera is installed at one end of the aforementioned vehicle, which takes pictures from an overhead perspective. An overhead crane monitoring system characterized in that the images captured by the panoramic camera show the lower storage area of ​​the overhead crane, a virtual vertical plane perpendicular to the traverse direction which is the direction of travel of the traverse carriage at the end face position of the other end of the traveling body, virtual vertical planes perpendicular to the direction of travel at both ends of the travel direction, and the traveling body, even when the position of the traveling body in the direction of travel changes.

2. The overhead crane monitoring system according to claim 1, characterized in that the panoramic camera has a horizontal field of view of 180° or more, and is positioned so that the horizontal field of view is centered on the traverse direction, which is the direction of travel of the traverse trolley.

3. The overhead crane monitoring system according to claim 1 or 2, characterized in that a wide display for displaying images captured by the panoramic camera is installed in the remote control room.

4. A means for measuring the travel position of the aforementioned traveling body, A means for measuring the traverse position of the aforementioned traverse trolley, A height position measuring means for measuring the height position of the lifting device by the aforementioned hoisting device, The overhead crane monitoring system according to any one of claims 1 to 3, further comprising a display control means for controlling the display of the traveling position of the traveling body measured by the traveling position measuring means, the traverse position of the traverse trolley measured by the traverse position measuring means, and the height position of the lifting device measured by the height position measuring means, on a display installed in a remote control room using monitoring images.

5. The display control means is The monitoring image displays a first display part representing the traveling body and a second display part representing the traversing trolley. The overhead crane monitoring system according to claim 4, characterized in that the first display part and the second display part are moved on the monitoring image based on the traveling position of the traveling body measured by the traveling position measuring means and the traverse position of the traverse trolley measured by the traverse position measuring means.

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