All-in-one tower crane controller, all-in-one tower crane, and tower crane control system

Abstract

An all-in-one tower crane controller (103-1), an all-in-one tower crane (103) and a tower crane control system (100). The all-in-one tower crane controller comprises: a motor control module, used for receiving a tower crane operation instruction, and driving a motor (103-2) of the all-in-one tower crane according to the tower crane operation instruction to operate, so that the motor drives the tower crane to operate; and a tower crane operation control module in communication connection with the motor control module, the tower crane operation control module being used for receiving a tower crane control instruction and / or a tower crane operation signal and used for sending the tower crane operation instruction. By using the all-in-one tower crane controller, connecting lines among devices are greatly reduced, the signal transmission efficiency of the all-in-one tower crane controller is improved, and the control capability and the anti-interference capability of the all-in-one tower crane controller are enhanced, so that the operation of tower cranes can be controlled more accurately, and the safety of the operation of tower cranes is improved.

Description

All-in-one controller, tower crane all-in-one and tower crane control system

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of Chinese patent application No. 202310718183.X filed on June 16, 2023, the contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to the technical field of tower crane control, and in particular to an all-in-one machine controller, an all-in-one tower crane, a tower crane control system and a tower crane control method. Background Art

[0004] Tower cranes are widely used material transport machines on construction sites. Their operations include vertical, horizontal, and rotational movement. Vertical movement is called hoisting, which includes ascending, stopping, and descending. Horizontal movement is called luffing, which includes forward, stopping, and reverse. Rotational movement is called slewing. Controlling tower crane operations requires control components such as controllers, inverters, motors, and sensors.

[0005] In the existing technology, the controller, inverter, motor, and sensor are respectively arranged at different positions of the tower crane, and long cables are required to connect the various components, resulting in long lines, poor anti-interference ability, high cost, and easy to cause safety accidents.

[0006] Summary of the Invention

[0007] The purpose of the embodiments of the present application is to provide an all-in-one controller, an all-in-one tower crane, a tower crane control system, and a tower crane control method.

[0008] In order to achieve the above-mentioned objectives, the present application provides, in a first aspect, an all-in-one controller, the all-in-one controller comprising:

[0009] The motor control module is used to receive the tower crane execution work instruction and drive the motor of the tower crane integrated machine to operate according to the tower crane execution work instruction, so that the motor drives the tower crane to execute the work operation;

[0010] The tower crane execution work control module is communicatively connected to the motor control module. The tower crane execution work control module is used to receive tower crane control instructions and / or tower crane execution work signals, and to send tower crane execution work instructions.

[0011] In an embodiment of the present application, the tower crane execution work control module also includes: a data storage submodule, which is used to store the tower crane execution work data; a data statistical analysis submodule, which is used to perform data statistical analysis on the tower crane control instructions and / or tower crane execution work signals; a fault diagnosis and alarm submodule, which is used to perform fault diagnosis on the tower crane execution work and to alarm when a fault is diagnosed.

[0012] A second aspect of the present application provides an integrated tower crane, comprising:

[0013] The motor is electrically connected to the all-in-one controller and is used to drive the tower crane to operate its working mechanism;

[0014] a motor encoder electrically connected to the motor and the all-in-one controller, the motor encoder being used to obtain motor signals and feed them back to the all-in-one controller; and

[0015] The above-mentioned all-in-one controller is installed as a whole with the motor and the motor encoder, and is used to receive tower crane control instructions and / or tower crane execution work signals, and drive the motor to work.

[0016] A third aspect of the present application provides a tower crane control system, the tower crane control system comprising:

[0017] The above-mentioned tower crane integrated machine, limiter, absolute value encoder and tower crane execution working mechanism;

[0018] The limiter is electrically connected to the tower crane integrated machine, and mechanically connected to the tower crane executive working mechanism. The limiter is used to obtain the limit signal of the tower crane executive working mechanism and feed it back to the tower crane integrated machine;

[0019] The absolute value encoder is electrically connected to the tower crane integrated machine, and is mechanically connected to the tower crane executive working mechanism. The absolute value encoder is used to obtain the position signal of the tower crane executive working mechanism and feed it back to the tower crane integrated machine;

[0020] The tower crane execution working mechanism is connected to the motor of the tower crane integrated machine through transmission, and is used for running the tower crane execution work under the drive of the motor of the tower crane integrated machine.

[0021] In an embodiment of the present application, the tower crane control system further includes: a tower crane controller electrically connected to the tower crane integrated machine and used for sending tower crane control instructions.

[0022] In an embodiment of the present application, the tower crane control system further includes: a brake, which is mechanically connected to the tower crane execution mechanism and the tower crane integrated machine respectively.

[0023] In an embodiment of the present application, the tower crane control system further includes: a three-phase AC power supply electrically connected to the tower crane integrated machine.

[0024] In an embodiment of the present application, the tower crane control system further includes: a braking resistor electrically connected to the tower crane integrated machine.

[0025] A fourth aspect of the present application provides a tower crane control method, which is applied to the above-mentioned tower crane control system. The control method includes:

[0026] The tower crane controller sends tower crane control instructions;

[0027] The tower crane execution work control module of the integrated machine controller receives the tower crane control instruction and sends the tower crane execution work instruction;

[0028] The motor control module of the integrated machine controller receives the tower crane execution work instruction and drives the motor to operate so that the motor drives the tower crane to perform the work operation.

[0029] In an embodiment of the present application, the control method also includes: the motor encoder obtains the motor signal of the tower crane's executing working mechanism and feeds it back to the all-in-one controller; the limiter obtains the limit signal of the tower crane's executing working mechanism and feeds it back to the all-in-one controller; the absolute value encoder obtains the position signal of the tower crane's executing working mechanism and feeds it back to the all-in-one controller.

[0030] The above technical solution, by designing an all-in-one controller, transfers the tower crane execution work control of the original tower crane controller to the all-in-one controller, and installs the all-in-one controller, motor, and motor encoder as one, reducing the connection between the all-in-one controller, motor, and encoder, and also reducing the electromagnetic interference caused by the line. At the same time, since the tower crane execution work control is transferred to the all-in-one controller, the absolute encoder, limiter, etc. no longer need to feed back signals to the tower crane controller, but only need to feed back to the all-in-one controller for processing. Therefore, the absolute encoder and limiter are directly connected to the tower crane all-in-one, the connection lines are further reduced, and the tower crane execution work control signal transmission is faster.

[0031] Other features and advantages of the embodiments of the present application will be described in detail in the subsequent detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The accompanying drawings are used to provide a further understanding of the embodiments of the present application and constitute a part of the specification. Together with the following detailed description, they are used to explain the embodiments of the present application but do not constitute a limitation on the embodiments of the present application. In the accompanying drawings:

[0033] FIG1 schematically shows a framework diagram of a tower crane control system according to an embodiment of the present application;

[0034] FIG2 schematically shows a flow chart of a tower crane control method according to an embodiment of the present application;

[0035] FIG3 schematically shows a frame diagram of a tower crane hoisting machine according to an embodiment of the present application;

[0036] FIG4 schematically shows another frame diagram of a tower crane hoisting machine according to an embodiment of the present application;

[0037] FIG5 schematically shows a framework diagram of a tower crane luffing integrated machine according to an embodiment of the present application;

[0038] FIG6 schematically shows another frame diagram of a tower crane luffing machine according to an embodiment of the present application. DETAILED DESCRIPTION

[0039] The following describes the specific embodiments of the present application in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present application and are not intended to limit the present application.

[0040] It should be noted that if the embodiments of the present application involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indications will also change accordingly.

[0041] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present application, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of such features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the fact that they can be implemented by ordinary technicians in this field. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0042] As shown in FIG1 , a tower crane control system 100 is provided. The tower crane control system 100 includes:

[0043] Tower crane integrated machine 103, limiter 104, absolute value encoder 102 and tower crane execution working mechanism 101;

[0044] The limiter 104 is electrically connected to the tower crane integrated machine 103 and mechanically connected to the tower crane execution working mechanism 101. The limiter 104 is used to obtain the limit signal of the tower crane execution working mechanism 101 and feed it back to the tower crane integrated machine 103;

[0045] The absolute value encoder 102 is electrically connected to the tower crane integrated machine 103, and the absolute value encoder 102 is mechanically connected to the tower crane execution working mechanism 101. The absolute value encoder 102 is used to obtain the position signal of the tower crane execution working mechanism 101 and feed it back to the tower crane integrated machine 103;

[0046] The tower crane execution mechanism 101 is in transmission connection with the motor 103 - 2 of the tower crane integrated machine 103 , and is used for operating the tower crane to execute work under the drive of the motor 103 - 2 of the tower crane integrated machine 103 .

[0047] The tower crane control system 100 further includes a tower crane controller 106, which is electrically connected to the tower crane integrated unit 103 and is configured to send tower crane control commands. The tower crane control system 100 further includes a brake 105, which is mechanically connected to the tower crane actuator 101 and the tower crane integrated unit 103. The tower crane control system also includes a three-phase AC power supply 107, which is electrically connected to the tower crane integrated unit 103. The tower crane control system also includes a brake resistor 108, which is electrically connected to the tower crane integrated unit 103.

[0048] To address the complex wiring issues associated with a tower crane controller driving a tower crane's operating mechanism, a tower crane integrated system is provided. This system shifts control of the tower crane's operating mechanism from the tower crane controller to the integrated system controller, which then controls the tower crane's operating mechanism. As shown in Figure 1, the tower crane integrated system 103 includes an integrated system controller 103-1, a motor 103-2, and a motor encoder 103-3. The integrated system controller 103-1, motor 103-2, and motor encoder 103-3 are integrated. Motor 103-2 is electrically connected to the integrated system controller 103-1 and is used to drive the tower crane's operating mechanism 101. The motor encoder 103-3 is electrically connected to both the motor 103-2 and the integrated system controller 103-1, respectively, to acquire motor signals and feed them back to the integrated system controller 103-1. The integrated system controller 103-1 is used to receive tower crane control commands and / or tower crane operating signals and drive the motor 103-2.

[0049] The existing tower crane execution motion control generally sends control instructions through the tower crane controller. The frequency converter receives the control instructions and drives the motor to work. The motor drives the tower crane execution working mechanism to operate. The absolute encoder, limit switch, motor encoder and other signal acquisition components respectively collect the tower crane execution working signals and then feed them back to the tower crane controller and / or frequency converter to form a closed-loop control. The tower crane controller is placed in the driver's cab, and the frequency converter is installed in the electrical cabinet. The electrical cabinet is installed in the driver's cab or near the driver's cab. The motors include lifting motor, luffing motor and slewing motor, which respectively control the lifting work, luffing work and slewing work, and are installed correspondingly on the balance arm, lifting arm and slewing mechanism. Since the tower crane controller, frequency converter and motor are all separately set up, they need to be connected through very long lines. At the same time, most of the tower crane's execution work is directly analyzed and controlled by the tower crane controller. Signal acquisition components such as absolute encoders and limiters also need a long line to be connected to the tower crane controller, so as to feedback the tower crane execution work signal to form a closed-loop control. Such a design will cause the high-voltage line to be too long, resulting in waste and easy to generate electromagnetic interference. At the same time, the frequency converter requires a separate electrical cabinet, which will also cause waste. The signal transmission from the controller to the frequency converter is slow, which brings safety problems to the tower crane control.

[0050] In response to the above problems, the present application designs an all-in-one controller 103-1, which has the motor control function of the frequency converter and the tower crane execution work control function of the original tower crane controller. The all-in-one controller is lowered and installed to the installation position of the motor, so that the all-in-one controller, motor, and motor encoder are installed as one. For example, the all-in-one controller is installed at the installation position of the lifting motor, the all-in-one controller is installed at the installation position of the variable amplitude motor, and the all-in-one controller is installed at the installation position of the rotary motor. The installation of each motor and encoder remains unchanged, so that the all-in-one controller, motor, and motor encoder of each tower crane execution action are installed as one. The installation as one here can be installed in one casing, or the all-in-one controller can be installed in one casing and connected to the motor and motor encoder, as long as they are physically connected in a close proximity. By designing an all-in-one controller, the tower crane execution work control of the original tower crane controller is transferred to the all-in-one controller, and the all-in-one controller, motor, and motor encoder are installed as one, reducing the connection between the all-in-one controller, motor, and encoder, and also reducing the electromagnetic interference caused by the line. At the same time, since the tower crane execution work control is transferred to the all-in-one controller, the absolute encoder, limiter, etc. no longer need to feed back signals to the tower crane controller, but only need to feed back to the all-in-one controller for processing. Therefore, the absolute encoder and limiter are directly connected to the tower crane all-in-one, the connection lines are further reduced, and the tower crane execution work control signal transmission is faster.

[0051] The all-in-one controller 103-1 includes a motor control module and a tower crane execution work control module. The tower crane execution work control module is communicatively connected to the tower crane execution work control module. The tower crane execution work control module and the motor control module can be integrated on a single microprocessor chip or two independent microprocessor chips, or can be integrated on a multi-core chip to enable communication between the actuator control module and the motor control module. The motor control module is used to receive tower crane execution work instructions and drive the motor 103-2 of the tower crane all-in-one 103 to operate according to the tower crane execution work instructions, so that the motor 103-2 drives the tower crane to execute work. The tower crane execution work control module is used to receive tower crane control instructions and / or tower crane execution work signals, and is used to send tower crane execution work instructions.

[0052] For example, after receiving a tower crane control instruction from the tower crane controller 106, the tower crane operation control module can send the tower crane operation instruction to the motor control module. After receiving the tower crane operation instruction, the motor control module can drive the motor 103-2 of the tower crane integrated unit 103 to operate according to the tower crane operation instruction, so that motor 103-2 drives the tower crane to perform operation. After the tower crane is performing operation, the tower crane operation control module can receive a tower crane operation signal to send a new tower crane operation instruction.

[0053] Assume that the tower crane execution control module receives a tower crane control instruction sent by the tower crane controller 106. It then generates a tower crane execution instruction based on the tower crane control instruction. After generating the tower crane execution instruction, the tower crane execution control module can send the tower crane execution instruction to the motor control module. Upon receiving the tower crane execution instruction, the motor control module can drive the motor 103-2 at a corresponding speed based on the tower crane execution instruction, so that the motor 103-2 drives the tower crane execution mechanism 101 to move. After the tower crane execution mechanism 101 moves, the tower crane execution control module can receive a motor signal fed back from the motor encoder 103-3. This motor signal carries first position information of the tower crane execution mechanism 101. The first position information can be determined by the motor encoder 103-3 based on the speed of the motor 103-2. The tower crane execution control module can also receive a position signal fed back from the absolute encoder 102. This position signal carries second position information of the tower crane execution mechanism 101. The absolute value encoder 102 is mechanically connected to the tower crane execution working mechanism, and the absolute value encoder 102 is electrically connected to the tower crane integrated machine 103.

[0054] After receiving the motor signal fed back by motor encoder 103-3 and the position signal fed back by absolute encoder 102, the crane execution control module can determine the position error between the first position information in the motor signal and the second position information in the position signal. If the position error is less than or equal to a first threshold, the crane execution control module can send a corresponding crane execution instruction to the motor control module, causing the motor control module to drive motor 103-2 to maintain its original speed according to the crane execution instruction, so that motor 103-2 drives the crane to execute the operation. If the position error is greater than the first threshold and less than a second threshold, the crane execution control module can send a corresponding crane execution instruction to the motor control module, causing the motor control module to drive motor 103-2 to decelerate according to the crane execution instruction, so that motor 103-2 drives the crane to execute the operation at a decelerated speed. The second threshold is greater than the first threshold. When the position error is greater than or equal to the second threshold, the tower crane execution work control module can send the corresponding tower crane execution work instruction to the motor control module, so that the motor control module controls the motor 103-2 to stop running according to the tower crane execution work instruction, so that the tower crane execution work stops running.

[0055] The above technical solution is used to improve the signal transmission efficiency between the various components of the tower crane integrated machine, enhance the control ability and anti-interference ability of the integrated machine controller, and can more accurately control the tower crane to perform work operations, thereby improving the safety of tower crane operations.

[0056] In one embodiment, the tower crane work execution control module also includes: a data storage submodule for storing tower crane work execution data; a data statistical analysis submodule for performing data statistical analysis on tower crane control instructions and / or tower crane work execution signals; a fault diagnosis and alarm submodule for performing fault diagnosis on the tower crane work and issuing an alarm when a fault is diagnosed.

[0057] The tower crane operation control module also includes a data storage submodule, a data statistics analysis submodule, and a fault diagnosis and alarm submodule. The data storage submodule is used to store tower crane operation data. The data statistics analysis submodule is used to receive tower crane control instructions and / or tower crane operation signals for statistical analysis. The fault diagnosis and alarm submodule is used to diagnose tower crane operation control faults and generate alarms when faults are detected.

[0058] For example, as shown in Figure 1, after the tower crane execution control module receives a tower crane control instruction sent by the tower crane controller 106, the data statistical analysis submodule can perform data statistical analysis on the received tower crane control instruction. After the data statistical analysis submodule performs data statistical analysis on the tower crane control instruction, the tower crane execution control module can send the tower crane execution instruction to the motor control module. The motor control module can receive the tower crane execution instruction and drive the motor 103-2 in the tower crane integrated unit 103 according to the tower crane execution instruction, so that motor 103-2 drives the tower crane to execute the operation. After motor 103-2 drives the tower crane to execute the operation, the data statistical analysis submodule in the tower crane execution control module can receive the tower crane execution signal and perform data statistical analysis. The data storage submodule can store the tower crane execution data. The fault diagnosis and alarm submodule can perform fault diagnosis on the tower crane execution operation and issue an alarm if a fault is diagnosed.

[0059] Assume that the tower crane execution control module receives a tower crane control instruction from the tower crane controller 106. It then generates a tower crane execution instruction based on the tower crane control instruction. After generating the tower crane execution instruction, the tower crane execution control module can send the tower crane execution instruction to the motor control module. Upon receiving the tower crane execution instruction, the motor control module can drive the motor 103-2 to operate at a corresponding speed based on the tower crane execution instruction, causing the motor 103-2 to drive the tower crane execution mechanism 101 to move.

[0060] After the tower crane execution working mechanism 101 moves, the limiter 104 can obtain the limit signal of the tower crane execution working mechanism 101 and send the limit signal to the tower crane integrated machine 103. Among them, the limit signal can be a lifting limit signal. The tower crane execution work control module of the integrated machine control 103-1 in the tower crane integrated machine 103 receives the lifting limit signal sent by the limiter 104. The data storage submodule in the tower crane execution work control module can store the tower crane execution work data at this time. Among them, the limiter 104 is electrically connected to the tower crane integrated machine 103, and the limiter 104 is mechanically connected to the tower crane execution working mechanism 101. The data statistical analysis submodule can perform statistical analysis on the lifting limit signal. In the case where the lifting limit signal is an upper limit signal, the tower crane execution work control module can send the corresponding tower crane execution work instruction to the motor control module, so that the motor control module controls the motor 103-2 to stop running according to the tower crane execution work instruction, so that the tower crane execution work mechanism 101 moves upward and is at the limit position corresponding to the upper limit signal or below the limit position. In the case where the lifting limit signal is a lower limit signal, the tower crane execution work control module can send the corresponding tower crane execution work instruction to the motor control module, so that the motor control module controls the motor 103-2 to stop running according to the tower crane execution work instruction, so that the tower crane execution work mechanism 101 moves downward and is at the limit position corresponding to the lower limit signal or above the limit position, which can ensure that the tower crane execution work mechanism 101 does not hit the top or fall to the ground when performing the lifting action.

[0061] The limit signal can also be an amplitude limit signal. The tower crane execution work control module of the integrated machine control 103-1 in the tower crane integrated machine 103 receives the amplitude limit signal sent by the limiter 104. The data statistical analysis submodule can perform statistical analysis on the amplitude limit signal. In the case where the amplitude limit signal is an internal limit signal, the tower crane execution work control module can send the corresponding tower crane execution work instruction to the motor control module, so that the motor control module controls the motor 103-2 to stop running according to the tower crane execution work instruction, so that the tower crane execution work mechanism 101 runs inward and is at the limit position corresponding to the internal amplitude signal or outside the limit position. When the amplitude change limit signal is an external limit signal, the tower crane execution work control module can send the corresponding tower crane execution work instruction to the motor control module, so that the motor control module controls the motor 103-2 to stop running according to the tower crane execution work instruction, so that the tower crane execution work mechanism 101 runs outward and is at the extreme position corresponding to the internal amplitude change signal or within the extreme position, which can ensure that the tower crane execution work mechanism 101 does not hit the inner and outer stoppers of the tower crane's boom when performing the amplitude change action, thereby ensuring safety.

[0062] In one embodiment, as shown in Figure 1 , a tower crane controller 106 is electrically connected to the tower crane integrated machine 103. The tower crane controller 106 can send tower crane control commands to the tower crane integrated machine 103. The integrated machine controller 103-1 in the tower crane integrated machine 103 can receive the tower crane control commands and drive the motor 103-2 in the tower crane integrated machine 103 to operate, thereby causing the motor 103-2 to drive the tower crane's executive working mechanism 101. The motor 103-2 is electrically connected to the integrated machine controller 103-1, and the motor 103-2 is in transmission connection with the tower crane's executive working mechanism 101.

[0063] Specifically, the all-in-one controller 103-1 includes a motor control module and a crane operation control module, which are communicatively connected. The crane operation control module receives crane control instructions from the crane controller 106, generates crane operation instructions based on the crane control instructions, and sends the crane operation instructions to the motor control module. Upon receiving the crane operation instructions, the motor control module drives motor 103-2 according to the crane operation instructions, causing motor 103-2 to drive the crane to perform its operations.

[0064] The tower crane control system 100 also includes a brake 105, which is mechanically connected to the tower crane's operating mechanism 101 and the tower crane integrated unit 103. After receiving a tower crane operating instruction, the motor control module drives motor 103-2 according to the instruction. While motor 103-2 is operating, brake 105 is engaged, allowing motor 103-2 to drive the tower crane's operating mechanism 101.

[0065] After the tower crane execution working mechanism 101 is in operation, the limiter 104 mechanically connected to the tower crane execution working mechanism 101 can obtain the limit signal of the tower crane execution working mechanism 101 and feed back the limit signal to the tower crane integrated machine 103. Among them, the limiter 104 is electrically connected to the tower crane integrated machine 103. After the tower crane execution work control module in the integrated machine controller 103-1 in the tower crane integrated machine 103 receives the feedback limit signal, the limit signal can be subjected to data statistical analysis by the data statistical analysis submodule in the tower crane execution work control module. The data storage submodule in the tower crane execution work control module can store the tower crane execution work data. The fault diagnosis and alarm submodule can perform fault diagnosis on the tower crane execution work and determine whether the position of the tower crane execution working mechanism exceeds the limit position. An alarm is issued when the limit position is exceeded.

[0066] After the tower crane execution mechanism 101 is in operation, the absolute value encoder 102 mechanically connected to the tower crane execution mechanism 101 can obtain the position signal of the tower crane execution mechanism 101 and feed the position signal back to the tower crane integrated machine 103. The tower crane integrated machine 103 is electrically connected to the absolute value encoder 102.

[0067] After the tower crane execution working mechanism 101 is in operation, the motor encoder 103-3 electrically connected to the motor 103-2 and the integrated machine controller 103-1 can obtain the motor signal and feed the motor signal back to the integrated machine controller 103-1.

[0068] After receiving the feedback position and motor signals, the tower crane execution control module in the integrated machine controller 103-1 in the tower crane integrated machine 103 can perform statistical analysis on the position and motor signals via the data statistical analysis submodule in the tower crane execution control module. The data storage submodule in the tower crane execution control module can store the tower crane execution data. The fault diagnosis and alarm submodule can perform fault diagnosis on the tower crane execution, determining whether the position of the tower crane execution mechanism 101 as fed back by the position signal and the position of the tower crane execution mechanism 101 as fed back by the motor signal are within an error range. If the error range is exceeded, an alarm is issued.

[0069] The tower crane control system 100 further includes a three-phase AC power supply 107, which is electrically connected to the tower crane integrated unit 103 and is used to power the tower crane integrated unit 103. The tower crane control system 100 further includes a braking resistor 108, which is electrically connected to the tower crane integrated unit 103 and is used for heat dissipation.

[0070] The above technical solution assembles the all-in-one controller, motor and motor encoder into a tower crane all-in-one machine, which greatly shortens the length of the connection line between the all-in-one controller and the motor, reduces the layout cost of the control line, enhances the control capability of the tower crane all-in-one machine, and can improve the accuracy of tower crane control.

[0071] FIG2 schematically shows a flow chart of a tower crane control method according to an embodiment of the present application. As shown in FIG2 , in one embodiment, a tower crane control method is provided, which is applied to the above-mentioned tower crane control system and includes the following steps:

[0072] Step 201: The tower crane controller sends a tower crane control instruction.

[0073] In step 202, the tower crane execution work control module of the integrated machine controller receives the tower crane control instruction and sends the tower crane execution work instruction.

[0074] In step 203, the motor control module of the integrated machine controller receives the tower crane execution work instruction and drives the motor to operate, so that the motor drives the tower crane to execute the work.

[0075] The tower crane's operating mechanism includes the luffing mechanism, hoisting mechanism, and slewing mechanism, specifically the crane's speed reducer, wire rope drum, sheave system, cargo hook, and crane body. The tower crane controller can send crane control commands. The all-in-one controller's tower crane operating control module receives these commands and issues them. The all-in-one controller's motor control module receives these commands and drives the motor, allowing the motor to operate the crane.

[0076] In one embodiment, the control method further includes: a motor encoder obtains a motor signal of the tower crane's executing working mechanism and feeds it back to the all-in-one controller; a limiter obtains a limit signal of the tower crane's executing working mechanism and feeds it back to the all-in-one controller; an absolute value encoder obtains a position signal of the tower crane's executing working mechanism and feeds it back to the all-in-one controller.

[0077] The motor encoder captures motor signals from the crane's actuators and feeds them back to the integrated controller. The limiter captures limit signals from the crane's actuators and feeds them back to the integrated controller. The absolute encoder captures position signals from the crane's actuators and feeds them back to the integrated controller. These captured signals are fed back to the integrated controller, forming a closed-loop control system.

[0078] For example, a tower crane control system may include a tower crane integrated unit, a limiter, an absolute encoder, and a tower crane actuator. The tower crane control system also includes a tower crane controller, a brake, a three-phase AC power supply, and a brake resistor. The limiter is electrically connected to the tower crane integrated unit and mechanically connected to the tower crane actuator. The absolute encoder is electrically connected to the tower crane integrated unit and mechanically connected to the tower crane actuator. The tower crane controller is electrically connected to the tower crane integrated unit. The brake is mechanically connected to the tower crane actuator and the tower crane integrated unit, respectively. The three-phase AC power supply is electrically connected to the tower crane integrated unit. The brake resistor is electrically connected to the tower crane integrated unit.

[0079] The tower crane system includes an integrated controller, a motor, and a motor encoder that are electrically connected to each other. The controller, motor, and motor encoder are integrated into one unit. The motor is in transmission connection with the tower crane's operating mechanism.

[0080] The all-in-one controller includes a motor control module and a tower crane execution control module that are communicatively connected. The tower crane controller can send tower crane control instructions to the tower crane all-in-one. The tower crane all-in-one can receive tower crane control instructions. Specifically, the tower crane execution control module of the all-in-one controller can receive tower crane control instructions and generate tower crane execution instructions based on the tower crane control instructions. After generating the tower crane execution instructions, the tower crane execution control module can send the tower crane execution instructions to the motor control module. After receiving the tower crane execution instructions, the motor control module can drive the motor to operate according to the tower crane execution instructions, so that the motor drives the tower crane to execute the work.

[0081] After the crane's actuator is operating, the motor encoder acquires the actuator's motor signal and feeds it back to the integrated controller. The limiter acquires the actuator's limit signal and feeds it back to the integrated controller. The absolute encoder acquires the actuator's position signal and feeds it back to the integrated controller.

[0082] The tower crane execution control module of the all-in-one controller can receive and process motor signals, limit signals, and position signals. The tower crane execution control module can include a data storage submodule, a data statistics and analysis submodule, and a fault diagnosis and alarm submodule. The data storage submodule can store operating data generated during the operation of the tower crane's execution mechanism. The data statistics submodule can analyze and compile statistics on the motor signals, limit signals, and position signals. The fault diagnosis and alarm submodule can perform fault diagnosis on the tower crane's execution mechanism based on the motor signals, limit signals, and position signals, and issue an alarm if a fault is detected.

[0083] In one embodiment, as shown in Figure 3, the tower crane integrated machine can be a tower crane hoisting machine 300. The tower crane hoisting machine 300 can include an integrated machine controller 301, a hoisting motor 302, and a motor encoder 303, all electrically connected to one another. The integrated machine controller 301, hoisting motor 302, and motor encoder 303 can be enclosed within the housing of the tower crane hoisting machine 300. The tower crane hoisting machine 300 can be electrically connected to an absolute encoder 304, a hoisting stopper 305, a three-phase AC power supply 306, and a brake resistor 307 of the tower crane control system, and can be mechanically connected to a hoisting brake 308 of the tower crane control system. The integrated machine controller 301 can include a controller and a frequency converter integrated within the same microprocessor chip; alternatively, each can be implemented in two separate microprocessor chips, communicatively connected to one another; or alternatively, it can be implemented within a multi-core chip, thereby implementing algorithmic control of the tower crane's hoisting control, motor control, and the absolute encoder 304 and hoisting stopper 305. This enhances the communication capabilities between the controller and the inverter, reduces signal interference caused by connecting these components separately, and strengthens the control capabilities of the integrated unit. The three-phase AC power supply 306 can power the tower crane hoisting integrated unit 300. The brake resistor 307 can be used for heat dissipation.

[0084] Specifically, the all-in-one controller 301 can be divided into two software projects stored in different areas. One software project can be used to control the hoisting motor 302, and the other software project can be used for the controller of the tower crane hoisting. For example, as shown in Figure 4, the all-in-one controller 401 can include a hoisting controller 401-1 and a motor controller 401-2. Among them, the hoisting controller 401-1 can be electrically connected to the hoisting limiter 407, the absolute value encoder 408 and the motor encoder 403, the motor encoder 403 is electrically connected to the hoisting motor 402, and the hoisting limiter 407 and the absolute value encoder 408 are both mechanically connected to the tower crane hoisting mechanism 405. The motor controller 401-2 can be electrically connected to the hoisting motor 402. The hoisting motor 402 is mechanically connected to the hoisting brake 404, and the hoisting motor 402 is transmission-connected to the tower crane hoisting mechanism 405.

[0085] The tower crane controller 406 can send tower crane control instructions to the tower crane hoisting integrated machine 400. Among them, the tower crane controller 406 is electrically connected to the tower crane hoisting integrated machine 400. After receiving the tower crane control instructions, the integrated machine controller 401 in the tower crane hoisting integrated machine 400 drives the hoisting motor 402 to run at a corresponding speed according to the tower crane control instructions. And control the hoisting brake 404 mechanically connected to the hoisting motor 402 to open, so that the tower crane hoisting mechanism 405 can perform the hoisting action. Specifically, the tower crane execution work control module in the integrated machine controller 401 can receive the tower crane control instructions and send the tower crane actuator work instructions to the motor control module. The motor control module can receive the tower crane actuator work instructions and drive the hoisting motor 402 to run according to the tower crane execution work instructions, so that the hoisting motor 402 drives the tower crane hoisting mechanism 405 to run.

[0086] The motor encoder 403 can obtain the motor signal of the hoisting motor 402 and send the motor signal to the integrated machine controller 401. The hoisting controller 401-1 of the integrated machine controller 401 can determine the speed of the hoisting motor 402 based on the motor signal, and further determine the first position information of the tower crane hoisting mechanism 405. The absolute value encoder 408 can obtain the position signal of the tower crane hoisting mechanism 405 and send the position signal to the integrated machine controller 401. The hoisting controller 401-1 of the integrated machine controller 401 can determine the second position information of the tower crane hoisting mechanism 405 based on the position signal. The hoisting controller 401-1 within the integrated machine controller 401 can determine the position error of the actuator based on the first position information and the second position information, and generate a tower crane execution work instruction based on the position error. The lifting controller 401-1 can transmit the tower crane execution work instruction to the motor controller 401-2 of the integrated machine controller 401, so that the motor controller 401-2 drives the lifting motor 402 to run at the corresponding operating speed according to the tower crane execution work instruction, thereby driving the tower crane lifting mechanism 405 to operate.

[0087] For example, if the position error is less than or equal to the first threshold, the hoisting controller 401-1 can transmit the corresponding tower crane execution work instruction to the motor controller 401-2. The motor controller 401-2 can then drive the hoisting motor 402 at the corresponding operating speed according to the tower crane execution work instruction. Assuming that the hoisting motor 402 has five operating speed levels, the motor controller 401-2 can drive the hoisting motor 402 to maintain the operating speed of the previous first speed level according to the tower crane execution work instruction. The hoisting brake 404 is released, and the hoisting motor 402 drives the tower crane hoisting mechanism 405 to perform the hoisting operation at the first speed level.

[0088] If the position error is greater than the first threshold and less than the second threshold, the hoisting controller 401-1 can transmit the corresponding tower crane operation instruction to the motor controller 401-2. The motor controller 401-2 can then move at any speed within the corresponding operating speed range according to the tower crane operation instruction. Assume that the corresponding operating speed range is from second to fourth gear. The hoisting brake 404 is opened, and the hoisting motor 402 drives the tower crane hoisting mechanism 405 to perform the hoisting operation at any speed among second, third, fourth, and fifth gears. The second threshold is greater than the first threshold.

[0089] If the position error is greater than or equal to the second threshold, the hoisting controller 401-1 can transmit the corresponding tower crane execution work instruction to the motor controller 401-2, and the motor controller 401-2 can stop operating according to the tower crane execution work instruction. The hoisting motor 402 stops operating, the hoisting brake 404 closes, and the tower crane hoisting mechanism 405 stops operating.

[0090] When the hoisting motor 402 stops running, the integrated machine controller 401 can send an alarm message to the tower crane controller 406 to notify the user to perform troubleshooting on the tower crane.

[0091] The lifting limiter 407 can detect the operating position of the tower crane hoisting mechanism 405 and send a limit signal corresponding to the operating position to the all-in-one controller 401. After detecting that the tower crane hoisting mechanism 405 has run to the contact point of the tower crane, the lifting limiter 407 can generate a limit signal and send it to the all-in-one controller 401. The lifting controller 401-1 in the all-in-one controller 401 can process the limit signal to determine that the lifting motor 402 needs to stop running. The instruction to stop the lifting motor 402 is transmitted to the motor controller 401-2, so that the motor controller 401-2 controls the lifting motor 402 to stop running, the lifting brake 404 is closed, and the tower crane hoisting mechanism 405 is within the limit position range corresponding to the limit signal.

[0092] Specifically, when the lifting limit signal is an upper limit signal, the lifting controller 401-1 in the integrated machine controller 401 can generate a corresponding tower crane execution work instruction based on the upper limit signal and send it to the motor controller 401-2, so that the motor controller 401-2 controls the lifting motor 402 to stop running according to the tower crane execution work instruction, so that the lifting mechanism moves upward and is at the limit position corresponding to the upper limit signal or below the limit position. When the lifting limit signal is a lower limit signal, the lifting controller 401-1 in the integrated machine controller 401 can generate a corresponding tower crane execution work instruction based on the lower limit signal and send it to the motor controller 401-2, so that the motor controller 401-2 controls the lifting motor 402 to stop running according to the tower crane execution work instruction, so that the lifting mechanism moves downward and is at the limit position corresponding to the lower limit signal or above the limit position, which can ensure that the lifting mechanism does not hit the top or fall to the ground when performing the lifting action.

[0093] In one embodiment, as shown in Figure 5, the tower crane integrated machine can be a tower crane luffing machine 500. The tower crane luffing machine 500 includes an electrically connected integrated machine controller 501, a luffing motor 502, and a motor encoder 503. The tower crane luffing machine 500 can be electrically connected to the crane's absolute encoder 504, a luffing stopper 505, a three-phase AC power supply 506, and a brake resistor 507, and can be mechanically connected to the crane's luffing brake 508. The integrated machine controller 501 can include a controller and a frequency converter integrated within the same microprocessor chip; alternatively, each can be implemented in two separate microprocessor chips, communicatively connected to each other; or implemented within a multi-core chip, thereby implementing algorithmic control of the tower crane's luffing control, motor control, and the absolute encoder 504 and luffing stopper 505. This enhances communication between the controller and frequency converter, reduces signal interference caused by separate connections between these components, and strengthens the control capabilities of the integrated machine. The three-phase AC power supply 506 can power the tower crane luffing machine 500. The braking resistor 507 can be used for heat dissipation.

[0094] Specifically, the all-in-one controller 501 can be divided into two software projects stored in different areas. One software project can be used to control the luffing motor 502, and the other software project can be used for the controller of the tower crane's luffing. For example, as shown in Figure 6, the all-in-one controller 601 may include a luffing controller 601-1 and a motor controller 601-2. The luffing controller 601-1 can be electrically connected to the luffing limiter 607, the absolute value encoder 608, and the motor encoder 603. The motor encoder 603 is electrically connected to the luffing motor 602. The luffing limiter 607 and the absolute value encoder 608 are both mechanically connected to the tower crane's luffing mechanism 605. The motor controller 601-2 can be electrically connected to the luffing motor 602. The luffing motor 602 is mechanically connected to the luffing brake 604 and is transmission-connected to the tower crane's luffing mechanism 605.

[0095] The tower crane controller 606 can send tower crane control instructions to the tower crane luffing machine 600. Among them, the tower crane controller 606 is electrically connected to the tower crane luffing machine 600. After receiving the tower crane control instructions, the all-in-one controller 601 in the tower crane luffing machine 600 drives the luffing motor 602 to run at a corresponding speed according to the tower crane control instructions. And control the luffing brake 604 mechanically connected to the luffing motor 602 to open, so that the tower crane luffing mechanism 605 can perform the luffing action. Specifically, the tower crane execution work control module in the all-in-one controller 601 can receive the tower crane control instructions and send the tower crane actuator work instructions to the motor control module. The motor control module can receive the tower crane actuator work instructions and drive the luffing motor 602 to run according to the tower crane execution work instructions, so that the luffing motor 602 drives the tower crane luffing mechanism 605 to run.

[0096] The motor encoder 603 can obtain the motor signal of the luffing motor 602 and send the motor signal to the all-in-one controller 601. The luffing controller 601-1 of the all-in-one controller 601 can determine the speed of the luffing motor 602 based on the motor signal, and then determine the first position information of the tower crane luffing mechanism 605. The absolute value encoder 608 can detect the position signal of the tower crane luffing mechanism 605 and send the position signal to the all-in-one controller 601. The luffing controller 601-1 of the all-in-one controller 601 can determine the second position information of the tower crane luffing mechanism 605 based on the position signal. The luffing controller 601-1 in the all-in-one controller 601 can determine the position error of the actuator based on the first position information and the second position information, and generate a tower crane execution work instruction based on the position error. The luffing controller 601-1 can transmit the tower crane work execution instruction to the motor controller 601-2 of the integrated machine controller 601, so that the motor controller 601-2 drives the luffing motor 602 to run at the corresponding operating speed according to the tower crane work execution, thereby driving the tower crane luffing mechanism 605 to operate.

[0097] For example, if the position error is less than or equal to the first threshold, the luffing controller 601-1 can transmit the corresponding tower crane operation instruction to the motor controller 601-2. Motor controller 601-2 can then drive the luffing motor 602 at the corresponding operating speed based on the tower crane operation instruction. Assuming that the luffing motor 602 has five operating speed levels, the motor controller 601-2 can drive the luffing motor 602 to maintain the previous speed at the first level based on the tower crane operation instruction. The luffing brake 604 is engaged, and the luffing motor 602 drives the tower crane luffing mechanism 605 to perform the luffing operation at the first speed level.

[0098] If the position error is greater than the first threshold and less than the second threshold, the luffing controller 601-1 can transmit the corresponding tower crane operation instruction to the motor controller 601-2. Motor controller 601-2 can then drive the luffing motor 602 to move at any speed within the corresponding operating speed range based on the tower crane operation instruction. Assume that the corresponding operating speed range is from second to fourth gear. The luffing brake 604 is engaged, and the luffing motor 602 drives the tower crane luffing mechanism 605 to perform the luffing operation at any speed among second, third, fourth, and fifth gears. The second threshold is greater than the first threshold.

[0099] If the position error is greater than or equal to the second threshold, the luffing controller 601-1 can transmit the corresponding tower crane operation instruction to the motor controller 601-2, and the motor controller 601-2 can stop operating according to the tower crane operation instruction. The luffing motor 602 stops operating, the luffing brake 604 closes, and the tower crane luffing mechanism 605 stops operating.

[0100] When the luffing motor 602 stops running, the all-in-one controller 601 may send an alarm message to the tower crane controller 606 to notify the user to perform troubleshooting on the tower crane.

[0101] The amplitude limiter 607 can detect the operating position of the tower crane's amplitude change mechanism 605 and send a limit signal corresponding to the operating position to the all-in-one controller 601. After detecting that the tower crane's amplitude change mechanism 605 has run to the tower crane's contact point, the amplitude limiter 607 can generate a limit signal and send it to the all-in-one controller 601. The amplitude change controller 601-1 in the all-in-one controller 601 can process the limit signal to determine that the amplitude change motor 602 needs to stop running. The instruction that the amplitude change motor 602 needs to stop is transmitted to the motor controller 601-2, so that the motor controller 601-2 controls the amplitude change motor 602 to stop running, the amplitude change brake 604 is closed, and the tower crane's amplitude change mechanism 605 is within the limit position range corresponding to the limit signal.

[0102] Specifically, when the amplitude change limit signal is an inner limit signal, the amplitude change controller 601-1 in the integrated machine controller 601 can generate a corresponding tower crane execution work instruction based on the inner limit signal and send it to the motor controller 601-2, so that the motor controller 601-2 controls the amplitude change motor 602 to stop running according to the tower crane execution work instruction, so that the amplitude change mechanism moves inward and is at the limit position corresponding to the inner limit signal or outside the limit position. When the amplitude change limit signal is an outer limit signal, the amplitude change controller 601-1 in the integrated machine controller 601 can generate a corresponding tower crane execution work instruction based on the outer limit signal and send it to the motor controller 601-2, so that the motor controller 601-2 controls the amplitude change motor 602 to stop running according to the tower crane execution work instruction, so that the amplitude change mechanism moves outward and is at the limit position corresponding to the outer limit signal or within the limit position, thereby ensuring that the amplitude change mechanism does not collide with the inner and outer stoppers of the tower crane's boom, thereby ensuring safety.

[0103] The above technical solution, by designing an all-in-one controller, transfers the tower crane execution work control of the original tower crane controller to the all-in-one controller, and installs the all-in-one controller, motor, and motor encoder as one, reducing the connection between the all-in-one controller, motor, and encoder, and also reducing the electromagnetic interference caused by the line. At the same time, since the tower crane execution work control is transferred to the all-in-one controller, the absolute encoder, limiter, etc. no longer need to feed back signals to the tower crane controller, but only need to feed back to the all-in-one controller for processing. Therefore, the absolute encoder and limiter are directly connected to the tower crane all-in-one, the connection lines are further reduced, and the tower crane execution work control signal transmission is faster.

[0104] FIG2 is a flow chart of a tower crane control method according to one embodiment. It should be understood that, although the steps in the flow chart of FIG2 are displayed sequentially as indicated by the arrows, these steps are not necessarily executed sequentially in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps, and these steps can be executed in other orders. Moreover, at least a portion of the steps in FIG2 may include multiple sub-steps or multiple stages, and these sub-steps or stages are not necessarily executed and completed at the same time, but can be executed at different times. The execution order of these sub-steps or stages is not necessarily sequential, but can be executed in rotation or alternation with other steps or at least a portion of the sub-steps or stages of other steps.

[0105] It should also be noted that the terms "comprises," "includes," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, method, commodity, or apparatus that includes a series of elements includes not only those elements but also other elements not explicitly listed, or includes elements inherent to such process, method, commodity, or apparatus. In the absence of further limitations, an element defined by the phrase "comprises a ..." does not exclude the presence of other identical elements in the process, method, commodity, or apparatus that includes the element.

[0106] The above are merely embodiments of the present application and are not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should all be included within the scope of the claims of the present application.

Claims

1. An all-in-one controller, characterized in that: The integrated machine controller comprises: A motor control module, the motor control module is used to receive a tower crane execution work instruction, and drive the motor of the tower crane integrated machine to operate according to the tower crane execution work instruction, so that the motor drives the tower crane to execute the work operation; A tower crane execution work control module, wherein the tower crane execution work control module is communicatively connected with the motor control module, and the tower crane execution work control module is used to receive tower crane control instructions and / or tower crane execution work signals, and is used to send tower crane execution work instructions.

2. The integrated machine controller according to claim 1, characterized in that: The tower crane execution work control module also includes: A data storage submodule is used to store the working data of the tower crane; A data statistical analysis submodule, used for performing data statistical analysis on the tower crane control instructions received and / or the tower crane execution work signals; The fault diagnosis and alarm submodule is used to diagnose the faults of the tower crane and to generate an alarm when a fault is found during the diagnosis.

3. A tower crane integrated machine, characterized in that: include: A motor is electrically connected to the integrated machine controller, and the motor is used to drive the tower crane to execute the working mechanism; A motor encoder is electrically connected to the motor and the all-in-one controller, and the motor encoder is used to obtain a motor signal and feed it back to the all-in-one controller; as well as According to any one of claims 1 to 2, the all-in-one controller is installed as a whole with the motor and the motor encoder, and is used to receive tower crane control instructions and / or tower crane execution work signals, and drive the motor to work.

4. A tower crane control system, characterized in that: The tower crane control system comprises: The tower crane integrated machine, limiter, absolute value encoder and tower crane execution working mechanism according to claim 3; The limiter is electrically connected to the tower crane integrated machine, the limiter is mechanically connected to the tower crane execution working mechanism, and the limiter is used to obtain the limit signal of the tower crane execution working mechanism and feed it back to the tower crane integrated machine; The absolute value encoder is electrically connected to the tower crane integrated machine, the absolute value encoder is mechanically connected to the tower crane execution working mechanism, and the absolute value encoder is used to obtain the position signal of the tower crane execution working mechanism and feed it back to the tower crane integrated machine; The tower crane execution working mechanism is drivingly connected to the motor of the tower crane integrated machine, and is used for running the tower crane to execute work under the drive of the motor of the tower crane integrated machine.

5. The tower crane control system according to claim 4, characterized in that: The tower crane control system also includes: The tower crane controller is electrically connected to the tower crane integrated machine and is used to send tower crane control instructions.

6. The tower crane control system according to claim 4, characterized in that: The tower crane control system also includes: A brake is mechanically connected to the tower crane execution working mechanism and the tower crane integrated machine respectively.

7. The tower crane control system according to claim 4, characterized in that: The tower crane control system also includes: A three-phase AC power supply is electrically connected to the tower crane integrated machine.

8. The tower crane control system according to claim 4, characterized in that: The tower crane control system also includes: A braking resistor is electrically connected to the tower crane integrated machine.

9. A tower crane control method, characterized in that: Applicable to the tower crane control system of claim 4, the control method comprising: The tower crane controller sends tower crane control instructions; The tower crane execution work control module of the integrated machine controller receives the tower crane control instruction and sends a tower crane execution work instruction; The motor control module of the integrated machine controller receives the working instruction of the tower crane and drives the motor to operate, so that the motor drives the tower crane to operate.

10. The tower crane control method according to claim 9, characterized in that: The control method further comprises: The motor encoder obtains the motor signal of the tower crane's working mechanism and feeds it back to the all-in-one controller; The limiter obtains the limit signal of the tower crane execution working mechanism and feeds it back to the integrated machine controller; The absolute encoder obtains the position signal of the tower crane's working mechanism and feeds it back to the integrated machine controller.

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