AI-based automation system for overhead cranes

Abstract

The present invention relates to an AI-based automation system for an overhead crane configured to automatically operate a bucket by measuring the height of accumulated waste and to automatically control the bucket by detecting swaying. The system comprises: an overhead crane that transports waste, etc., accumulated in a storage space of a storage facility to a hopper using a bucket; a waste height measuring device (WPSS: Waste Pit Scanning System) that measures the height of waste using a 3D LiDAR scanning system, collects images within the waste storage facility (ST), and links with a crane part; a crane work sequence collection device (TMS: Task Managing System) that improves crane operation efficiency in a work management area by separately controlling 'inflow / mixing / leveling / input'; a crane control device consisting of an ACCS (Automatic Crane Control System), a WPMS (Waste Pit Management System), and a MOS (Monitoring & Operating System); and an Anti-Sway device that performs bucket sway prevention control. A crane operation and PLC expansion device comprising a control part including an industrial computer, a UPS, and a PLC (Programmable Logic Controller);It is configured to include, wherein the ACCS (Automatic Crane Control System) performs motion control and automated operation of the crane by linking with automation PLC programs and LiDAR data-based information collected in the crane pool automatic operation area by AI-based automation software, and controls the operation of the overhead crane and the waste accumulated in the storage (ST) by the TCP HUB and the control room (OP); the WPMS (Waste Pit Management System) manages the amount of waste brought in and the amount of waste stored in the management area of ​​the waste storage (ST) based on LiDAR data; the MOS (Monitoring & Operating System) monitors the crane operation status, the status of the waste storage amount, and various information through a screen; and the Anti-Sway device includes an infrared camera (IR Camera) installed in the vertical downward direction of the crane's traversing section / a BEACON installed horizontally above the hook;The present invention proposes an AI-based automated overhead crane system characterized by, when shaking and tilting of a bucket or hook are detected by one or more of an angle sensor installed in the inner or outer casing of a bucket / an IMU sensor (Inertial Measurement Unit Sensor) with built-in accelerometer, gyroscope, and geomagnetic sensor installed in the outer or inner casing of a bucket / calculating the position of the bucket or hook using a recorded ANGLE value and controlling tracking, and controlling the shaking of the bucket or hook by giving a speed command in the reverse direction of the shaking by means of high speed, low speed, and direction signals of a driving inverter or a traversing inverter (80). Accordingly, the present invention has a LiDAR Scanning System for measuring the height of waste installed on the upper side of the storage tank, so that when waste exceeding a standard value accumulates, the bucket is automatically operated to transfer it to the hopper, and an infrared camera that detects the shaking of the bucket and transmits a signal to move the trolley to reduce shaking Automatic control by AI makes the operation of the crane safer and more convenient.

Description

Technology Field

[0001] The present invention relates to an overhead crane for transporting waste materials filled in a storage tank (ST), and more specifically, to an AI-based automation system for an overhead crane configured to automatically operate a bucket by measuring the height of the piled waste materials and to automatically control the bucket by detecting shaking. Background Technology

[0002] Generally, a crane or hoist refers to a machine that lifts heavy objects and moves them in vertical and horizontal directions (east, west, south, and north on a plane), and is also called a crane. Such cranes are used in various factories, ports, warehouses, etc., for moving materials, products, or other heavy objects in three dimensions, and are used to handle much heavier loads compared to hoists or chain blocks.

[0004] Meanwhile, the overhead crane is a commonly used type of crane, and it is named as such because it is installed on the ceilings of buildings such as factories and warehouses. Such overhead cranes lay rails along walls facing each other and span beam-shaped rails that run perpendicularly to these rails.

[0005] A running device, a traversing device (hereinafter referred to as a trolley), and a hoisting machine are installed on such rails, and heavy objects can be lifted or lowered using a hook or bucket from the trolley equipped with the hoisting device. By appropriately adjusting the horizontal and vertical movements of the running and traversing devices on the rails, heavy objects can be transported to any location within a building. Smaller ones are operated manually by a person, but usually, a person rides in a cab suspended from a girder and operates the vehicle while looking out at the transported object suspended from the hook from the cab.

[0006] Published Patent Application No. 10-2023-0095146 provides a waste storage facility that can be efficiently operated when storing waste in a waste storage area, and such a waste storage facility is equipped with an overhead crane.

[0007] However, these conventional overhead cranes are operated manually by an operator, and consequently, there was a problem in that workers had to directly intervene to resolve unexpected situations. The problem to be solved

[0008] The purpose of the present invention is to provide an AI-based automated overhead crane system that improves the system by measuring the height of accumulated waste using a LiDAR scanning system and automatically operating a bucket to transport the waste when it exceeds a standard value, and provides the necessary waste height information to ensure optimal operation of the bucket when the waste is accumulated high.

[0009] In addition, the present invention has another objective of providing an AI-based automated system for an overhead crane that is improved to automatically detect the tilt of the bucket changing as the crane moves and reduce shaking by installing an infrared camera and an angle sensor for detecting bucket shaking on the trolley and the bucket, respectively or in parallel. means of solving the problem

[0010] The AI-based automation system for an overhead crane according to the present invention comprises, for an overhead crane that transports waste materials accumulated in a storage space of a storage facility to a hopper using a bucket, a waste height measuring device (WPSS: Waste Pit Scanning System) that measures the height of the waste using a 3D LiDAR scanning system, collects images within the waste storage facility (ST), and is linked with a crane part; a crane work sequence collection device (TMS: Task Managing System) that improves the efficiency of crane operations in a work management area by separately controlling 'inflow / mixing / leveling / input'; a crane control device comprising an ACCS (Automatic Crane Control System), a WPMS (Waste Pit Management System), and a MOS (Monitoring & Operating System); an anti-sway device that performs bucket shaking prevention control; and a crane operation and PLC expansion device comprising a control part including an industrial computer, a UPS, and a PLC (Programmable Logic Controller).It is configured to include, wherein the ACCS (Automatic Crane Control System) performs motion control and automated operation of the crane by linking with automation PLC programs and LiDAR data-based information collected in the crane pool automatic operation area by AI-based automation software, and controls the operation of the overhead crane and the waste accumulated in the storage (ST) by the TCP HUB and the control room (OP); the WPMS (Waste Pit Management System) manages the amount of waste brought in and the amount of waste stored in the management area of ​​the waste storage (ST) based on LiDAR data; the MOS (Monitoring & Operating System) monitors the crane operation status, the status of the waste storage amount, and various information through a screen; and the Anti-Sway device includes an infrared camera (IR Camera) installed in the vertical downward direction of the crane's traversing section / a BEACON installed horizontally above the hook; The technical feature is that when shaking and tilting of a bucket or hook are detected by one or more of an angle sensor installed in the inner or outer casing of a bucket / an IMU sensor (Inertial Measurement Unit Sensor) with built-in accelerometer, gyroscope, and geomagnetic sensor installed in the outer or inner casing of a bucket / the position of the bucket or hook is calculated and tracked using the recorded ANGLE value, and the shaking of the bucket or hook is controlled by giving a speed command in the reverse direction of the shaking by the high speed, low speed, and direction signals of the driving inverter or traversing inverter (80). Effects of the invention

[0011] According to the AI-based overhead crane automation system of the present invention, a LiDAR Scanning System for measuring the height of waste is installed on the upper side of the storage tank, so that when waste exceeding a standard amount is accumulated, the bucket is automatically operated to transfer it to the hopper. The LiDAR Scanning System provides the necessary height information of the waste so that the bucket operates optimally when the waste is accumulated high, and an infrared camera and an angle sensor that detect the tilt and shaking of the bucket and transmit a signal to move the position of the trolley to reduce shaking are automatically controlled by AI, thereby making the operation of the crane safer and more convenient. Brief explanation of the drawing

[0012] FIG. 1 is a cross-sectional view of a waste storage facility equipped with a ceiling crane according to the present invention. FIG. 2 is a block diagram of an AI-based overhead crane automation system according to the present invention. FIG. 3 is a front view of an overhead crane according to the present invention, FIG. 4 is a front view showing the shaking state of the bucket of the present invention, FIG. 5 is a front view showing the process of reducing shaking of the bucket of the present invention. FIG. 6 is a block diagram showing an automation system for an overhead crane as an embodiment of the present invention. FIG. 7 is an example of a network configuration of an AI-based overhead crane automation system according to the present invention. Specific details for implementing the invention

[0013] A preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0014] The AI-based overhead crane automation system of the present invention is installed in a storage facility (ST) that temporarily stores various wastes, recyclables, various materials, agricultural and livestock products, etc., as shown in FIG. 1, and the present invention shows an example of its application to a system that collects and discharges various wastes.

[0016] In the above storage facility (ST), a storage space (1) is formed for temporarily storing various types of waste collected by transporting them by a vehicle, and a hopper (2) is formed on the upper side of the storage space (1) for collecting and transporting the waste, and a driver's cabin (3) and a rail (4) are formed on the ceiling.

[0018] On the upper side of the above rail (4), a bucket (13) that moves by a bogie (10) is connected to a wire rope (11), and a plurality of LiDAR Scanning Systems (110) are installed on the upper side of the bogie (10).

[0020] LiDAR (Light Detection And Ranging) is a device for detection and distance measurement using light. It refers to a remote sensing method (detection using a sensor from a distance) that illuminates an object using near-infrared, visible, and ultraviolet light, and measures the distance by detecting the reflected light through an optical sensor.

[0022] That is, the LiDAR Scanning System (110) applied in the present invention is intended to measure the height of collected waste by emitting infrared rays onto waste filled in the storage space (1), and it is preferable to install two or more LiDAR Scanning Systems (110) at intervals. The number of LiDAR Scanning Systems installed is determined according to the area of ​​the waste storage (ST).

[0024] When waste accumulates above a standard level in a specific part of the storage space (1), the above LiDAR Scanning System (110) measures the gap and then moves the cart (10), and then lowers the bucket (13) to pick up the waste and moves it to the hopper (2) to drop it, and provides the necessary height information of the waste so that the bucket (13) operates optimally when the waste is piled high.

[0026] The interface for implementing the LiDAR Scanning System (110) of the present invention is one of Ethernet, TCP / IP, or UDP / IP, and can be implemented by shaping the state of the storage space (1) and the amount of stored waste along with the measurement of height.

[0028] The AI-based overhead crane automation system of the present invention, as illustrated in FIG. 2, is an overhead crane that transports waste materials accumulated in the storage space of a storage facility (ST) to a hopper using a bucket, comprising: a waste height measuring device (WPSS: Waste Pit Scanning System) (100) that measures the height of the waste using a 3D LiDAR Scanning system (110), collects images within the waste storage facility (ST), and links with the crane part; and a crane work sequence collection device (TMS: Task Managing System) (200) that controls 'inflow / mixing / leveling / input' separately to improve the efficiency of crane operations in the work management area; The crane control device (300) comprises an ACCS (Automatic Crane Control System) (310) that performs motion control and automated operation of the crane by linking with LiDAR DATA-based information collected in the crane pool automatic operation area by AI-based automation software and an automation PLC program, a WPMS (Waste Pit Management System) (320) that manages the amount of waste stored in the management area of ​​the waste storage (ST) based on the amount of incoming waste and LiDAR Data, and a MOS (Monitoring & Operating System) (330) that monitors the crane operation status, the amount of waste stored, and various information through a screen; an Anti-Sway device (400) that performs BUCKET sway prevention control; and a control part (510) that includes an Industrial Computer, a UPS, and a PLC (Programmable Logic Controller).

[0030] In the present invention, the 3D LiDAR Scanning system (110) is a technical configuration for recognizing the surrounding environment and crane status, the waste height measuring device (WPSS: Waste Pit Scanning System) (100) is a technical configuration for measuring the height of waste, the crane work sequence collection device (TMS: Task Managing System) (200) is a technical configuration for determining the crane work sequence through information analysis and judgment, the ACCS (Automatic Crane Control System) (310) is a technical configuration for detailed control of crane operation according to the crane work sequence, the WPMS (Waste Pit Management System) (320) is a technical configuration for managing the amount of waste stored in the waste storage (ST), and the MOS (Monitoring & Operating System) (330) is a technical configuration for checking the status of various information through a screen.

[0032] At this time, the waste height measuring device (WPSS: Waste Pit Scanning System) (100) installs 3D LiDAR sensors at multiple locations within the waste storage (ST) and applies a LiDAR Scanning System (110) using a 3D scanner to visualize the state of the storage (ST) and the amount of stored raw materials.

[0034] Meanwhile, the above-mentioned Anti-Sway device (400) detects shaking through mutual sensing between an infrared camera (IR Camera) (410) and a BEACON (411) or detects the tilt of the bucket by an angle sensor (420). It then calculates the position of the hook using the shaking value recorded through the real-time infrared camera (410) and the tilt value detected by the angle sensor (420) to control tracking, and suppresses the shaking of the bucket by giving a speed command in the reverse direction of the shaking through the high speed, low speed, and direction signals of the driving inverter (70) or the traverse inverter (80).

[0035] Additionally, for shaking detection used in the above-mentioned Anti-Sway device (400), an IMU sensor (Inertial Measurement Unit Sensor) (430) with built-in accelerometer, gyroscope, and geomagnetic sensors installed in the outer or inner casing of the bucket can be used.

[0037] Once established, oscillation has the property of moving continuously due to gravity, and the principle of a clock pendulum (pendulum motion) applies.

[0038] Therefore, since the period and magnitude of the shaking are determined by the length (L) of the line, for the same amount of movement of the trolley and crane, it moves with a small amplitude when the line is short, and moves with a large amplitude when the line is long.

[0039] At this time, the magnitude of the shaking is determined by the acceleration of the trolley and the crane, and if the traversing of the trolley and the traveling of the crane occur in parallel, the shaking is excessive.

[0041] The sway removal principle applied to the anti-sway device (400) according to the present invention applies forward and reverse control.

[0042] That is, in forward control, if the inverter output of the moving device is increased in the same direction as the weight (increase motor speed), the moving device moves in the direction of the weight and the shaking is eliminated, and in reverse control, if the inverter output of the moving device is increased in the opposite direction of the weight (increase motor speed), the moving device moves in the reverse direction of the weight and the shaking is eliminated.

[0044] In the case of conventional lateral / travel manual movement, the motor speed is controlled (multi-speed 1 to 4 stages) by the inverter output according to an artificial manual driving signal. However, to resolve the problem that an unskilled operator cannot accurately control the shaking and tilt of the bucket when operating, the lateral / travel anti-sway driving method applied in the present invention senses the position of the bucket by an infrared camera (410) or an angle sensor (420) during crane operation, detects the tilt, transmits the position data to an anti-sway control unit, and automatically controls the inverter output and motor speed according to the position data to prevent shaking.

[0046] Infrared rays are emitted from the transmitting part of the infrared camera (410), and infrared rays are received through the photodiode of the receiving part to accurately detect shaking and tilt, and are transmitted to the Anti-Sway device (400) by wired or short-range wireless communication. The BEACON (411) and the ANGLE SENSOR (420) also detect shaking and tilt by wired or short-range wireless communication and transmit them to the Anti-Sway device (400).

[0047] That is, the infrared camera (410) and BEACON (411) of the present invention perform the same role as the angle sensor (420), and depending on the situation, the infrared camera (410) and BEACON (411) may be omitted.

[0049] At this time, in one embodiment of the present invention, the infrared camera (410) is installed in the vertical lower direction of the crane traversing section, the BEACON (411) is installed horizontally on the upper part of the hook, and the angle sensor (420) is installed in the outer or inner casing of the bucket.

[0051] Meanwhile, the bucket (13) is configured to be able to move up and down by means of a sheave block (12) connected by a wire rope (11) as shown in FIG. 3, and an infrared camera (410) and an angle sensor (420) are installed on the lower side of the trolley (10) to measure the range of movement and tilt when the bucket (13) shakes.

[0052] As shown in FIG. 4, the infrared camera (410) and angle sensor (420) measure the angle of movement of the bucket (13) when the bucket (13) shakes left and right around the center line, and transmit a signal to reduce the angle of shaking by generating a load on the shaking of the bucket (13).

[0053] That is, when the shaking bucket (13) moves in the direction of the centerline as shown in FIG. 5, the output of the bogie (10) is increased so that it moves in the same direction, thereby reducing the angle of the trajectory of the bucket (13) and reducing the shaking.

[0055] The AI-based overhead crane automation system of the present invention configured as described above undergoes a process as shown in the block diagram in FIG. 6 as an example, and all operations are automatically performed by AI, and the waste accumulated in the storage (ST) and the operation of the overhead crane are controlled by the TCP HUB (31) and the control room (OP).

[0057] A pair of LiDAR Scanning Systems (110) installed on the upper side of the storage (ST) emit infrared light to measure the height of the waste and transmit the image signal to the TCP HUB (31), and the infrared camera (410) transmits the shaking of the bucket (13) to the TCP HUB (31) through the ABS encoder (20).

[0058] At this time, the TCP HUB (31) reduces shaking by moving the bogie (10) in the same direction as the shaking direction of the bucket (13) through the anti-shake controller (driving) (50) and the anti-shake controller (traversing) (51).

[0060] In addition, the driving inverter (70), the traversing inverter (80), and the hoisting inverter (90) are operated by the signals of the proximity sensor (traversing) (60) and the proximity sensor (driving) (61), and the driving inverter (70) and the traversing inverter (80) each operate the driving motor (71) and the traversing motor (81), and the hoisting inverter (90) operates the hoisting motor (91), and these are controlled by the driving assistance device (92).

[0061] And the angle sensor (420) installed in the bucket (13) and the wired / wireless transmitter (41) installed in the sheave block (12) transmit a signal to the anti-shake controller (lifting) (52) to control the lifting and lowering of the bucket (13).

[0062] In one embodiment of the present invention, the wired / wireless transmitter (41) can be implemented as a wired method or a short-range wireless communication method, such as BEACON (411).

[0064] Figure 7 schematically illustrates a network configuration as an embodiment of an AI-based overhead crane automation system according to the present invention.

[0065] In other words, the manager can monitor the control room, receive information collected from the Crane PLC, ACCS PLC, Anti-Sway Controller, and LiDAR Controller via a router, and verify that the overhead crane is operating automatically in the Waste Pit.

[0067] Accordingly, the present invention has the effect of making the operation of the crane safer and more convenient by automatically controlling an infrared camera (410) by AI, which detects the shaking of the bucket (13) and transmits a signal to reduce shaking, thereby providing the necessary height information for the bucket to operate optimally when the waste is piled high, and by moving the cart (10) by transmitting a signal, a LiDAR Scanning System (110) that measures the height of the waste is installed on the upper side of the storage tank, so that when waste is piled up above a standard value, the bucket (13) is automatically operated to transfer it to the hopper, and when the waste is piled high, the infrared camera (410) that detects the shaking of the bucket (13) and transmits a signal is automatically controlled by AI. Explanation of the symbols

[0068] 10: Bogie 11: Wire rope 12 : Sheave Block 13 : Bucket 20 : ABS Encoder 31 : TCP HUB 41 : Wired / Wireless Transmitter 50 : Anti-shake controller (driving) 51 : Anti-shake controller (traversing) 52 : Anti-shake controller (lifting) 60 : Proximity sensor (traversing) 61 : Proximity sensor (driving) 70 : Driving inverter 71 : Driving motor 80 : Traverse inverter 81 : Traverse motor 90 : Hoisting inverter 91 : Hoisting motor 92 : Driving assistance device 100: Waste Pit Scanning System (WPSS) 110: 3D LiDAR Scanning system 200 : Crane Work Sequence Establishment Device (TMS: Task Managing System) 300: Crane control device 310: ACCS (Automatic Crane Control System) 320: WPMS (Waste Pit Management System) 330: MOS (Monitoring & Operating System) 400 : Anti-Sway device 410 : Infrared camera (IR Camera) 411 : BEACON 420 : Angle Sensor 430 : IMU Sensor (Inertial Measurement Unit Sensor) 500: Crane Operation and PLC Expansion Device 510: Control Part

Claims

Claim 1 In an overhead crane that transports waste materials accumulated in the storage space of a storage facility to a hopper using a bucket, the crane comprises: a waste height measuring device (WPSS: Waste Pit Scanning System) (100) that measures the height of the waste using a 3D LiDAR Scanning system (110), collects images within the waste storage facility (ST), and links with the crane part; a crane work sequence collection device (TMS: Task Managing System) (200) that improves the efficiency of crane operations in the work management area by controlling 'inflow / mixing / leveling / input' separately; a crane control device (300) composed of an ACCS (Automatic Crane Control System) (310), a WPMS (Waste Pit Management System) (320), and a MOS (Monitoring & Operating System) (330); and an Anti-Sway device (400) that performs bucket shaking prevention control. A crane operation and PLC expansion device (500) comprising a control part (510) including an industrial computer, a UPS, and a PLC (Programmable Logic controller);It is configured to include, wherein the ACCS (Automatic Crane Control System) (310) performs motion control and automated operation of the crane by linking with an automated PLC program and LiDAR DATA-based information collected in the crane pool automatic operation area by AI-based automation software, and controls the operation of the overhead crane and the waste piled in the storage (ST) by the TCP HUB (31) and the control room (OP); the WPMS (Waste Pit Management System) (320) manages the amount of waste brought in and the amount of waste stored in the management area of ​​the waste storage (ST) based on LiDAR data; the MOS (Monitoring & Operating System) (330) monitors the crane operation status, the status of the waste storage amount, and various information through a screen; and the Anti-Sway device (400) includes an infrared camera (IR Camera) (410) installed in the vertical lower direction of the crane's traversing section, a beacon (411) installed horizontally on the upper part of the hook, and an angle installed in the inner or outer casing of the bucket. An AI-based overhead crane automation system characterized by, when shaking and tilting of a bucket (13) or hook are detected by any one or more of a sensor (420) / an IMU sensor (Inertial Measurement Unit Sensor) (430) with built-in acceleration, gyroscope, and geomagnetic sensors installed in the outer or inner casing of a bucket / calculating the position of the bucket (13) or hook using a recorded ANGLE value and controlling tracking, and controlling the shaking of the bucket (13) or hook by giving a speed command in the reverse direction of the shaking by high speed, low speed, and direction signals of a driving inverter (70) or a traversing inverter (80).; Claim 2 In claim 1, the AI-based overhead crane automation system is characterized in that the waste height measuring device (WPSS: Waste Pit Scanning System) (100) applies a LiDAR Scanning System (110) that visualizes the state of the storage and the amount of stored raw materials using a 3D scanner by installing 3D LiDAR sensors at each of the multiple locations within the waste storage. Claim 3 In claim 2, the above LiDAR Scanning System (110) is configured with an interface of any one of Ethernet, TCP / IP, or UDP / IP, and is characterized by measuring the height of the collected waste and visualizing the state of the storage space (1) and the amount of stored waste by emitting infrared rays to the waste filled in the storage space (1), thereby forming an AI-based overhead crane automation system. Claim 4 An AI-based automated system for an overhead crane, characterized in that, in the first paragraph, a plurality of LiDAR Scanning Systems (110) are installed at intervals on the upper side of a storage (ST), and the LiDAR Scanning Systems (110) are configured to emit and receive infrared rays from waste to measure the height of the waste, thereby providing waste storage status information, and the bucket (13) is operated according to the established work instructions by analyzing the status information, and an infrared camera (410) and a Beacon (411) are installed on the overhead crane to detect shaking of the bucket or hook, or an angle sensor (420) or an IMU sensor (430) is installed on the bucket to detect shaking of the bucket or hook and the degree of tilt of the bucket, and the crane is moved to reduce shaking. Claim 5 delete Claim 6 delete

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