阅读说明：本技术 一种起重机自动预警系统及方法 (Automatic early warning system and method for crane ) 是由 朱长建 史金飞 赵振东 于 2020-06-10 设计创作，主要内容包括：本发明公开了一种起重机自动预警系统及方法,包括：数据采集模块,用于采集起重机的作业数据和影像信息；数据存储模块,用于存储起重机作业边界数据；数据分析模块,用于读取起重机当前作业数据,根据所述的作业数据分析起重机的运行参数与作业边界的差值；信息显示模块,用于读取并显示起重机的运行参数与作业边界的差值,显示允许向作业边界进一步操作的图形和或数值。本发明通过起重机上安装的双目立体视觉摄像头和传感器,利用起重机车载计算机,建立起重机、吊装物体、吊装环境的三维模型,动态分析三者碰撞的风险,以图形或和声音形式提醒操作者,为起重作业安全提供保障。(The invention discloses an automatic early warning system and method for a crane, which comprises the following steps: the data acquisition module is used for acquiring operation data and image information of the crane; the data storage module is used for storing crane operation boundary data; the data analysis module is used for reading the current operation data of the crane and analyzing the difference value between the operation parameter of the crane and the operation boundary according to the operation data; and the information display module is used for reading and displaying the difference value between the operating parameter of the crane and the operation boundary, and displaying graphs and/or numerical values which allow further operation to the operation boundary. According to the invention, through the binocular stereoscopic vision camera and the sensor which are arranged on the crane, the crane onboard computer is utilized to establish a three-dimensional model of the crane, a hoisting object and a hoisting environment, the risk of collision of the crane, the hoisting object and the hoisting environment is dynamically analyzed, an operator is reminded in a graphic or sound mode, and the safety of hoisting operation is guaranteed.)

1. An automatic early warning system of a crane, comprising:

the system comprises a plurality of rotatable cameras arranged at different positions on a crane, a data storage module, a data acquisition module and a data acquisition module, wherein the cameras are used for acquiring attitude images, hoisting environment images and hoisting object images of the crane;

the data acquisition module comprises a sensor system arranged in the crane and is used for acquiring the operation data of the crane, wherein the operation data is the operation parameters of the crane main mechanism;

the data storage module is used for storing initial data of the crane and acquired image data;

the data analysis module is used for reading the current operation data of the crane, calculating the difference value between the operation parameters of the crane and the operation boundary according to the operation data, performing three-dimensional correction on the acquired image data, converting the acquired image data into a three-dimensional model and transmitting the three-dimensional model to the information display module;

the information display module is arranged in a crane control room or on a wireless remote controller, and can display the difference value between the operation parameter and the operation boundary of the crane, display the three-dimensional space model of the crane and a hoisting object, display the difference value in a graph and/or numerical value mode and display a warning signal.

2. The automatic early warning system of the crane as claimed in claim 1, which comprises an audible and visual alarm device connected with the data analysis module, and comprises an audible alarm unit and/or a light alarm unit for alarming sound and/or light according to the output of the data analysis module.

3. The automatic early warning system for cranes according to claim 1, wherein the position where the camera is mounted on the crane comprises: a boom, a control cabin and/or a crane turret.

4. The automatic early warning system of claim 1, wherein the operational parameters comprise: the system comprises amplitude variation operation parameters of the crane, rotation operation parameters of the crane, boom extension operation parameters of the crane, lifting operation parameters of the crane, parameters or states of other operation boundaries of the crane, operation space of the crane and image information of a lifted object.

5. The automatic early warning system for cranes of claim 1, wherein the initial data comprises factory designed rated load capacity chart data, factory designed operational boundary data for cranes, operational boundary data set by crane operators.

6. An automatic early warning method of a crane, based on the automatic early warning system of any one of claims 1-5, characterized by comprising the following steps:

(1) reading the pre-stored rated load capacity chart data of the factory design of the crane, the factory design operation boundary data of the crane and/or the operation boundary data set by the operator of the crane in the module as the operation boundary of the crane;

(2) reading the current operation parameters of the crane in real time;

(3) calculating the difference value between the current operation parameter and the operation boundary in real time; setting the area close to the boundary as a warning area, namely setting the difference value within a certain range as the warning area;

(4) when the calculated difference value falls into the warning area, the result is displayed, and an alarm is given to an operator in a graphic, sound or light mode.

7. The automatic early warning method for the crane according to claim 6, wherein the step (4) further comprises the following steps: according to the three-dimensional space model of the crane, the hoisted object and the hoisting environment, performing operation collision analysis, wherein the collision analysis comprises the following steps:

(1) analyzing the collision between the crane and the hoisting space, and judging the risk that the crane equipment approaches or touches obstacles around the hoisting operation space;

(2) analyzing the collision between the crane and the hoisted object, and judging the risk of the crane equipment approaching or touching the hoisted object;

(3) and analyzing the collision between the hoisting space and the hoisting object, and judging the risk that the hoisting object of the crane approaches or touches obstacles around the hoisting operation space.

8. The automatic early warning method for the crane according to claim 6, wherein the warning areas comprise a primary warning area, a secondary warning area, … … and an n-level warning area, n is greater than or equal to 2, the difference between the current operation parameter in the primary warning area and the operation boundary is the smallest, and the difference between the current operation parameter in the n-level warning area and the operation boundary is the largest.

9. The automatic early warning method for a crane according to claim 8, wherein when the difference falls into a higher-level warning area, a graphical, sound or light alarm is performed at a low frequency, a low decibel or a low brightness; when the difference falls into a lower level warning zone, a graphical, sound or light alarm is made at high frequency, high decibel or high brightness.

10. The automatic early warning method for the crane according to claim 6, wherein the frequency, decibel or brightness of the graphic, sound or light alarm is performed as a direct proportional function or an increasing function according to the change of the difference value from large to small when the difference value falls into the warning area.

Technical Field

The invention relates to an automatic early warning system and method for a crane.

Background

The crane is easy to exceed a rated or operator preset safety boundary when the crane performs actions such as lifting heavy objects, amplitude change (changing the angle of a cargo boom, and generally changing the working amplitude of a lifting hook through amplitude change), rotation and the like of lifting operation, so that heavy objects fall, the cargo boom is bent, and even serious accidents such as car damage and human death are caused. In order to ensure the safety of the hoisting operation, the crane is generally provided with an overload protection device, and the overload operation is protected and/or prompted during the operation of the crane, wherein the overload protection device comprises a rated hoisting capacity limiter and an indicator.

However, the prior art has two disadvantages: firstly, although the operation parameters such as lifting capacity, actual torque percentage, working amplitude and the like are displayed, the relationship between the crane or a heavy object and the boundary is not expressed in a graphical form, the difference value between the current operation parameter of the crane and the operation boundary cannot be quantized, the operator cannot be intuitively guided to move, and a space for further operation to the operation boundary is allowed, so that the operator cannot intuitively judge the danger level; secondly, in the prior art, when the crane approaches or reaches overload operation, the buzzer is used as a sound alarm device to prompt an operator, but the frequency of the alarm sound is not changed according to the danger degree, so that the closer the crane approaches the danger, the closer the operator needs to carefully observe and operate the crane with caution.

Disclosure of Invention

The purpose of the invention is as follows: the invention aims to provide an automatic early warning system and method for a crane, which dynamically analyze the collision risk of the crane, a hoisting object and a hoisting environment, remind an operator in the form of figures, sounds and the like and provide guarantee for the safety of hoisting operation.

The technical scheme is as follows: the invention relates to an automatic early warning system of a crane, which comprises:

the system comprises a plurality of rotatable cameras arranged at different positions on a crane, wherein the cameras are connected with a data storage module and used for acquiring attitude images, hoisting environment images and hoisting object images of the crane;

the data acquisition module comprises a sensor system arranged in the crane and is used for acquiring the operation data of the crane, wherein the operation data is the operation parameters of the crane main mechanism;

the data storage module is used for storing initial data of the crane and acquired image data;

the data analysis module is used for reading the current operation data of the crane, calculating the difference value between the operation parameters of the crane and the operation boundary according to the operation data, performing three-dimensional correction on the acquired image data, converting the acquired image data into a three-dimensional model and transmitting the three-dimensional model to the information display module;

the information display module is arranged in a crane control room or on a wireless remote controller, and can display the difference value between the operation parameter and the operation boundary of the crane, display the three-dimensional space model of the crane and a hoisting object, display the difference value in a graph and/or numerical value mode and display a warning signal.

An automatic early warning method of a crane is based on the automatic early warning system and comprises the following steps:

(1) reading the pre-stored rated load capacity chart data of the factory design of the crane, the factory design operation boundary data of the crane and/or the operation boundary data set by the operator of the crane in the module as the operation boundary of the crane;

(2) reading the current operation parameters of the crane in real time;

(3) calculating the difference value between the current operation parameter and the operation boundary in real time; setting the area close to the boundary as a warning area, namely setting the difference value within a certain range as the warning area;

(4) when the calculated difference value falls into the warning area, the result is displayed, and an alarm is given to an operator in a graphic, sound or light mode.

The step (4) further comprises the following steps: according to the three-dimensional space model of the crane, the hoisted object and the hoisting environment, performing operation collision analysis, wherein the collision analysis comprises the following steps:

(1) analyzing the collision between the crane and the hoisting space, and judging the risk that the crane equipment approaches or touches obstacles around the hoisting operation space;

(2) analyzing the collision between the crane and the hoisted object, and judging the risk of the crane equipment approaching or touching the hoisted object;

(3) and analyzing the collision between the hoisting space and the hoisting object, and judging the risk that the hoisting object of the crane approaches or touches obstacles around the hoisting operation space.

Has the advantages that: compared with the prior art, the invention has the following remarkable advantages:

(1) according to the invention, the camera is arranged to acquire the three-dimensional image of the crane and establish the three-dimensional model of the crane, so that the collision conditions of the crane, a hoisted object and a hoisting environment can be dynamically analyzed, and the pose state of the crane can be clearly and visually displayed.

(2) The active early warning system and the active early warning method for the hoisting operation, provided by the invention, have the advantages that the danger degree is displayed in a graphical mode when the operation boundary is approached, the sound alarm frequency is changed according to the danger degree, the operation risk of the hoisting operation can be reduced, through a hierarchical automatic early warning mechanism, reference information for next operation can be provided more comprehensively and more accurately in a quantized mode when an operator operates a crane, the current state can be judged more quickly, and the applicability is wide.

Drawings

FIG. 1 is a schematic diagram of the early warning system of the present invention;

FIG. 2 is a flow chart of the present invention for identifying the working space of the lifting operation;

FIG. 3 is a flow chart of the early warning method of the present invention;

fig. 4 is a schematic illustration of the present invention showing an example of the operation of the horn to adjust the working amplitude.

Detailed Description

The technical scheme of the invention is further explained by combining the attached drawings.

As shown in fig. 1, the present invention provides a structure diagram of an active early warning system for crane operation according to an embodiment, a crane operator can actively obtain a difference between a current operation parameter and an operation boundary when using a crane equipped with the active early warning system, a display can visually display a range of further operation in the form of a graph or a numerical value, and an alarm sound can be emitted according to a degree of approaching the operation boundary, and the frequency of the alarm sound is higher as the operation boundary is approached.

The system of the present embodiment is mainly composed of the following parts:

the data acquisition module 1 comprises a sensor system arranged in the crane, wherein the sensor system comprises a length sensor 101, an angle sensor 102, a force sensor 103, a camera 104, and other sensors and/or limit switches related to crane operation, and is used for acquiring crane operation data, and the operation data comprises running state information of a crane main mechanism. The data acquisition module 1 transmits the acquired hoisting operation parameters, video information and the like to the crane controller to be used as input variables of the current posture of the hoisting operation.

The data storage module 4 mainly includes a memory 401 for storing initial data of the crane and collected image data. The initial data includes: the method comprises the steps of storing rated load-lifting capacity chart data of factory design of a crane, or storing operation boundary data of factory design of the crane, or storing operation boundary data set by a crane operator, or storing operation boundary data calculated according to a binocular camera. The memory 401 may be a separate storage hardware, integrated into the crane controller 201, or integrated into the display 301.

The data analysis module 2 mainly comprises a crane controller 201, can read the current operation data and images of the crane from the data acquisition module 1, and firstly establishes a three-dimensional space model of the crane, a hoisted object and a hoisting environment. The difference value between the current operation parameter of the crane and the operation boundary is obtained by comparing the operation boundary parameter with the operation boundary parameter in the data storage module 4, and is sent to the information display module 3 if necessary.

The information display module 3 is arranged in a crane control room or on a wireless remote controller and comprises a display 301 and an audible and visual alarm device 302, and the audible alarm device 302 can also be integrated into the display 301. The information display module 3 can display the crane and the three-dimensional space model of the hoisted object according to the configuration condition of the crane, display the difference value between the current operation parameter and the operation boundary in a graph and/or numerical value mode, and display a warning signal.

Fig. 2 is a flow chart of the identification of the hoisting operation space of the present invention, the flow is mainly completed in the data analysis module 2, and the flow mainly includes the following steps:

and S272, reading image information such as the current operation space, the aerial position of a hoisting object, the hoisting environment and the like of the crane by using the rotatable camera 104 arranged on the crane. The positions where the camera can be installed on the crane include: the crane boom, the control room and the crane rotary table. The camera 104 can be fixedly installed or can be installed on a cloud deck, and the pitch angle of the camera is adjusted according to the operation posture of the crane. The camera is preferably a binocular camera.

And S273, the data analysis module 2 performs three-dimensional correction on the image acquired by the binocular camera 104 according to the pre-stored image calibration parameters and the image algorithm.

And S274, the data analysis module 2 carries out three-dimensional space reconstruction according to the image acquired by the camera 104, and establishes a three-dimensional space model of the crane operation space.

And S275, the data analysis module 2 carries out three-dimensional space reconstruction according to the image acquired by the camera 104, and establishes a three-dimensional space model of the hoisted object.

S276, the data acquisition module 1 acquires operation posture parameter information of the length sensor 101, the angle sensor 102 and the force sensor 103 on the crane, and other sensors and/or limit switches related to hoisting operation.

And S277, the data analysis module 2 carries out three-dimensional space reconstruction according to the crane attitude parameter information acquired by the data acquisition module 1 and the crane three-dimensional model stored by the data storage module 4, and establishes the crane three-dimensional space model.

And S278, the data analysis module 2 performs collision analysis according to the crane hoisting operation space established in the S274 and the crane three-dimensional model established in the S277, and transmits the analysis result to the information display module 3. And analyzing the collision between the crane and the hoisting space, and judging the risk that the crane equipment approaches or touches obstacles around the hoisting operation space.

And S279, the data analysis module 2 performs collision analysis according to the crane hoisting object established in S275 and the crane three-dimensional model established in S277, and transmits the analysis result to the information display module 3. And (4) analyzing the collision between the crane and the hoisted object, and judging the risk of the crane equipment approaching or touching the hoisted object.

And S280, the data analysis module 2 performs collision analysis according to the crane hoisting space three-dimensional model established in S274 and the hoisted object three-dimensional model established in S275, and transmits the analysis result to the information display module 3. And analyzing the collision between the hoisting space and the hoisting object, and judging the risk that the hoisting object of the crane approaches or touches obstacles around the hoisting operation space.

S281, the data analysis module 2 transmits the collision analysis result to the information display module 3 for displaying.

As shown in fig. 3, the present invention provides a main flow chart of an active early warning method for hoisting operation according to an embodiment, which mainly includes the following steps:

s202, reading the current operation parameters of the crane, which mainly comprises the following contents:

1) amplitude variation related operation parameters: the amplitude variation angle of the crane boom, the length of the crane boom, the movement direction of the amplitude variation operation and the like. The working amplitude of the crane can be calculated according to the variables.

2) Relevant operation parameters of the hoisting mechanism: the pressure of the amplitude variation oil cylinder, the length of the crane boom, the angle of the crane boom, the operation multiplying power, the setting of the operation working condition, and the current lifting or falling action. The current actual lifting capacity is calculated.

3) Gyration-related parameters: angle of rotation, etc. The current rotation angle and the movement direction of the rotation operation of the crane can be obtained.

4) Boom telescoping related parameters: boom length, boom angle, whether the boom is in the extension or retraction motion direction, etc.

And S203, reading the operation boundaries in the data storage module, wherein the operation boundaries can be the maximum boundaries in the rated load-lifting capacity chart of the crane or the operation boundaries set by the operator of the crane.

The method mainly comprises several or one of the following operation boundaries, or a combination of the operation boundaries:

1) the amplitude operation boundary mainly comprises the maximum angle and the minimum angle of the amplitude allowed by the crane, and can also be the maximum amplitude and the minimum amplitude allowed to work.

2) The lifting operation boundary mainly comprises the maximum lifting capacity of the crane allowed to lift.

3) The crane reach boundary mainly comprises the maximum arm length allowing the boom to reach out.

4) And the slewing operation boundaries comprise a left slewing boundary and a right slewing boundary.

And S204, calculating the difference value between the work boundary parameter and the current work parameter according to the parameters of S203 and S202.

S205, according to the difference value between the job boundary parameter calculated in S204 and the current job parameter, the following processing is carried out:

1) when the relative operation of the hoisting operation causes the crane to be smaller than the starting warning area point (for example, approaching 90% of the rated allowable boundary), the data analysis module 2 sends an instruction to the information display module 3 to display in a safe manner, and the active early warning system does not participate in the control of the display content of the display 301.

2) When the crane approaches the operation boundary start warning area point (for example, approaches 90% of the rated allowable boundary) by the related operation of the hoisting operation, the data analysis module 2 sends a command to the information display module 3, the display 301 starts to send the difference value of the operation parameter of the crane and the operation boundary to the information display module for numerical value and/or graph, and the audible and visual alarm device 302 warns at a low frequency.

3) When the crane reaches or exceeds a boundary value point (for example, 100% of a rated allowable boundary) by related operation of hoisting operation, the data analysis module 2 sends a command to the information display module 3, the display 301 displays the information of the reached operation boundary in a numerical value and/or graphic mode, at the moment, the display 301 displays that the current crane reaches or exceeds the operation boundary obviously, and the sound-light alarm device 302 warns at a high frequency.

4) When the related operation of the hoisting operation enables the hoisting operation parameters to be between the starting warning area point and the operation boundary point, the data analysis module 2 sends an instruction to the information display module 3, the display 301 sends the difference value between the operation parameters and the operation boundary of the crane to the information display module for a numerical value and/or a graph, the graph or the numerical value changes along with the danger degree, for example, a primary warning area, a secondary warning area, … … and an n-level warning area are arranged, n is more than or equal to 2, the difference value between the current operation parameters and the operation boundary in the primary warning area is minimum, and the difference value between the current operation parameters and the operation boundary in the n-level warning area is maximum. When the difference falls into a higher warning area, the alarm of the graph, the sound or the light is carried out at low frequency, low decibel or low brightness; when the difference falls into the lower warning zone, a graphical, audible or light alarm is made at a high frequency, high decibel or high intensity. The audible and visual alarm device 302 alarms with a proportional function frequency or an increasing frequency.

And S206, displaying by using graphs and characters according to the comparison result of the difference value of the operation boundary parameter and the current operation parameter in the S204.

And S207, according to the comparison result of the difference value between the operation boundary parameter and the current operation parameter in the S204, performing sound warning in a mode that the closer to the operation boundary, the higher the sound warning frequency.

As shown in fig. 4, the present invention provides a schematic display diagram of an automatic warning method, which takes the operation of the amplitude changing mechanism to adjust the working amplitude as an example.

The figure 501 is a schematic diagram of a current hook for hoisting a heavy object; 502 is the distance from the center line of the current lifting hook to the working amplitude working boundary line, wherein NC is the difference value between the set working amplitude and the current working amplitude; 503 is the working amplitude working boundary line; 504 is the hook centerline; 505 is the distance from the rotation center line of the crane to the working amplitude working boundary line, wherein NB is a set working amplitude boundary value; 506 is the distance from the current hook center line to the crane rotation center line, wherein NA is the current working amplitude value; 507 is a rotation central line of the crane; 508 is a crane luffing mechanism; 509 is the jib.