Automatic Calibration Rig for Container Crane Sensors
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Solution Overview
Problem
Manual calibration of container cranes is time-consuming, labor-intensive, and prone to errors, requiring significant manpower and disrupting production, while also being unsafe for maintenance personnel to work alone in active container blocks.
Innovation Solution
An automatic calibration system using a calibration rig with markers at known positions, combined with sensors, allows for minimal manual intervention, enabling faster and more accurate calibration of container cranes by calculating position parameters for load and target position systems, independent of human skill and experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual calibration procedures are used, then calibration can be performed with simple equipment, but calibration time is excessive (4-8 hours per crane) and productivity is reduced
Solution Approach 1:
The patent replaces manual mechanical calibration procedures with an automated optical measurement system. Sensors (cameras, laser scanners) automatically capture images of markers on the crane, and computer algorithms calculate position parameters, eliminating the need for manual measurement and calculation processes that previously took 4-8 hours per crane.
Solution Approach 2:
The calibration system performs self-calibration by automatically capturing images, processing data, and calculating position parameters without requiring manual intervention. The system uses pre-installed markers and automated image processing to determine crane position parameters independently, reducing calibration time to minutes while maintaining accuracy.
2Reliability
If manual calibration is performed by maintenance personnel, then calibration can be adjusted based on experience, but safety risks increase when working alone in active container blocks
Solution Approach 1:
The patent replaces manual calibration operations with automated sensor-based measurement systems. Cameras and laser scanners mounted on the crane automatically capture position data, eliminating the need for maintenance personnel to physically measure and mark positions, thereby removing safety risks associated with working in active container blocks while maintaining calibration reliability through automated data processing.
Solution Approach 2:
The patent introduces markers as intermediary objects that facilitate automated measurement. These markers are placed on the crane structure and detected by sensors, serving as intermediaries between the physical crane position and the digital measurement system, enabling accurate calibration without human intervention in hazardous areas.
3Measurement precision
If extensive manual fine-tuning is performed, then calibration accuracy can be improved, but calibration time increases and disrupts production
Solution Approach 1:
The patent replaces manual fine-tuning with automated image processing and computer-based parameter calculation. Sensors capture precise images of markers, and algorithms automatically calculate position parameters with high precision, eliminating the need for time-consuming manual adjustments while achieving consistent measurement accuracy across all cranes in a block.
Solution Approach 2:
The patent creates digital copies of physical positions through photographic images of markers. Instead of manual measurement and interpretation, the system captures precise visual copies of marker positions and uses computer algorithms to extract position parameters, achieving high measurement precision automatically without manual fine-tuning.
4Productivity
If calibration is performed on cranes in active production blocks, then production continuity is maintained, but calibration must be interrupted and restarted multiple times
Solution Approach 1:
The patent replaces manual calibration procedures with an automated system that can rapidly capture images and calculate parameters without interruption. Sensors continuously capture marker positions, and computer algorithms process data in real-time, allowing calibration to proceed without stopping crane operations, thereby maintaining production continuity while eliminating calibration interruptions.
Data Source
AI summary
A device, method and system for automatic calibration of a container crane, the container crane being controlled by a system including a first sensor (LPS) and/or a second sensor (TPS), are provided. A calibration rig is arranged in a fixed position and includes a plurality of markers, each arranged at a known and fixed position and distance relative to one another. The markers may include a first marker with a first visual appearance, or active marker and/or a second marker with a second visual appearance, or passive marker. The active marker is preferably an illumination source, such as an IR source. A method for calibrating a container crane using the calibration device and a container control system including the calibration device and one or more computer programs are also described.