CN114148901B - Control system and method for grabbing amount of gantry crane grab bucket - Google Patents
Control system and method for grabbing amount of gantry crane grab bucket Download PDFInfo
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- CN114148901B CN114148901B CN202111647523.1A CN202111647523A CN114148901B CN 114148901 B CN114148901 B CN 114148901B CN 202111647523 A CN202111647523 A CN 202111647523A CN 114148901 B CN114148901 B CN 114148901B
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- 238000000034 method Methods 0.000 title claims abstract description 36
- 230000007246 mechanism Effects 0.000 claims abstract description 148
- 239000000463 material Substances 0.000 claims abstract description 68
- 229910000831 Steel Inorganic materials 0.000 claims description 59
- 239000010959 steel Substances 0.000 claims description 59
- 238000009412 basement excavation Methods 0.000 claims description 20
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- 230000005484 gravity Effects 0.000 abstract description 18
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C3/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith and intended primarily for transmitting lifting forces to loose materials; Grabs
- B66C3/02—Bucket grabs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/48—Automatic control of crane drives for producing a single or repeated working cycle; Programme control
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Abstract
本发明公开了一种门机抓斗抓取量控制系统及其相应的控制方法，系统包括支持机构位置传感器、开闭机构位置传感器、支持机构速度编码器、开闭机构速度编码器、PLC控制器和操作面板，操作面板上设置有显示屏、物料选择旋钮、深挖调整旋钮、深挖启动按钮和自动抓取启动按钮；门机抓斗控制方法基于门机抓斗抓取量控制系统实现；该门机抓斗抓取量控制系统及其相应的控制方法能够有效提高接卸比重较高货物的作业效率，同时也避免了因超负荷对门机自身的伤害，保证了人机的安全；与此同时，该系统操作简单，降低了对门机司机操作水平的要求，减轻了司机的劳动强度，客观上也降低了发生事故的风险。
The invention discloses a grab amount control system for a gantry crane grab bucket and a corresponding control method thereof. The system comprises a support mechanism position sensor, an opening and closing mechanism position sensor, a support mechanism speed encoder, an opening and closing mechanism speed encoder, a PLC controller and an operation panel, and the operation panel is provided with a display screen, a material selection knob, a deep digging adjustment knob, a deep digging start button and an automatic grab start button; the gantry crane grab bucket control method is implemented based on the gantry crane grab amount control system; the gantry crane grab bucket grab amount control system and the corresponding control method thereof can effectively improve the operation efficiency of loading and unloading goods with a relatively high specific gravity, and at the same time, also avoid damage to the gantry crane itself due to overload, and ensure the safety of man and machine; at the same time, the system is simple to operate, reduces the requirements on the operation level of the gantry crane driver, reduces the driver's labor intensity, and objectively reduces the risk of accidents.
Description
Technical Field
The invention relates to the field of wharf loading and unloading operations, in particular to a control system and a control method for grabbing quantity of a grab bucket of a gantry crane.
Background
At present, the rated lifting capacity of a door machine commonly used in wharf unloading operation is 40t, the proportion of the unloaded goods is various and is basically between 1.9 and 2.8, but the grab buckets with different sizes are reserved to adapt to materials with different proportions, so that the cost is high, and the time and the labor are consumed for replacing the grab buckets. Therefore, the large-bucket-capacity light grab bucket and the small-bucket-capacity grab bucket which are commonly adopted in the prior loading and unloading sites, but the production operation efficiency of the grab buckets with different capacities for receiving and unloading goods with different specific gravities is obviously different.
In general, the receiving and unloading efficiency of the goods with lower specific gravity is higher because a light grab bucket with large bucket capacity is usually selected when the goods with lower specific gravity are received and unloaded, the weight of a full grab bucket is basically lower than 40t when the goods are grabbed, the technical requirements on the operation of a driver of a door machine are lower, the operation efficiency of the driver with relatively higher operation level is not greatly different from that of the driver with relatively lower operation level, when the goods with higher specific gravity are received and unloaded, the grab bucket with small bucket capacity can cause that the weight of the grab bucket can not reach 40t even if the grab bucket is full of the goods, the operation capacity of the door machine is wasted, and the total weight of the grab bucket with large bucket capacity can exceed the maximum operation load of the door machine when the grab bucket with large bucket capacity is selected for grabbing, so that an overload phenomenon is caused, the door machine driver can only reopen the grab bucket, part of the goods is leaked, and the grab bucket is closed again. The process of opening and closing the hopper again causes time waste and reduces the working efficiency. However, the door operator with high operation level can manually control the grabbing amount of the grab bucket according to the closing degree of the grab bucket in the grabbing process and the weight display in the cab, so that the grabbing amount is basically kept at 40t, the process of opening and closing the grab bucket again is avoided, the operation efficiency is ensured, the goods with high specific gravity are received and unloaded, the technical requirements on the operation of the door operator are higher, the operation efficiency of the door operator with relatively higher operation level is higher than that of the door operator with relatively lower operation level, but the door operator with high operation level is few, and each driver cannot reach a very high level.
To sum up, in order to improve the working efficiency when receiving and unloading the goods with higher specific gravity, it is necessary to develop a device which can be used in cooperation with the grab operation and effectively improve the working efficiency when receiving and unloading the goods with higher specific gravity, starting from the control of the grab.
Disclosure of Invention
The invention aims to provide a door machine grab bucket grabbing amount control system for improving the operation efficiency of receiving and unloading cargoes with higher specific gravity.
The invention further aims at a control method realized based on the door machine grab bucket grabbing amount control system.
For this purpose, the technical scheme of the invention is as follows:
a door operator grapple grip control system comprising:
a) A supporting mechanism position sensor mounted on a rotating mechanism of a hoist of the supporting mechanism to collect a rotational position signal of a motor drive shaft of the hoist of the supporting mechanism;
b) An opening and closing mechanism position sensor mounted on a rotation mechanism of a hoist of the opening and closing mechanism to collect a rotation position signal of a motor drive shaft of the hoist of the opening and closing mechanism;
c) A supporting mechanism speed encoder mounted on a motor drive shaft of a hoist of the supporting mechanism to collect a rotational speed signal of the motor drive shaft of the hoist of the supporting mechanism;
d) The speed encoder of the opening and closing mechanism is arranged on a motor driving shaft of the winch of the opening and closing mechanism so as to detect a rotating speed signal of the motor driving shaft of the winch of the opening and closing mechanism;
e) The PLC controller is arranged in a control box arranged on the side surface of a linkage table in a cab of the gantry crane, is respectively and electrically connected with a supporting mechanism position sensor and an opening and closing mechanism displacement sensor, is respectively and electrically connected with a supporting mechanism speed encoder and an opening and closing mechanism speed encoder, is respectively and electrically connected with a winch electromechanical mechanism of the supporting mechanism through a frequency converter A, is electrically connected with a winch electromechanical mechanism of the opening and closing mechanism through a frequency converter B, is electrically connected with an overload system which is arranged in a matching way with the grab bucket, and is electrically connected with the overload system of the grab bucket
F) The control box comprises an operation panel, a display screen, a material selection knob, a deep-digging adjusting knob, a deep-digging starting button and an automatic grabbing starting button, wherein the display screen is electrically connected with a PLC (programmable logic controller), the material selection knob is electrically connected with the PLC through a digital quantity input module, the deep-digging adjusting knob is connected with the PLC through an analog quantity input module, the deep-digging starting button is electrically connected with the PLC, the automatic grabbing starting button is electrically connected with the PLC, and the deep-digging adjusting knob is an electrodeless knob.
Further, the support mechanism position sensor and the opening and closing mechanism position sensor may alternatively be hall sensors mounted on the motor rotor assembly.
Further, an upper display frame and a lower display frame are arranged on the display screen, the upper display frame is used for displaying a value corresponding to the current gear of the material selection knob, and the lower display frame is used for displaying a value corresponding to the current position of the deep-excavation adjusting knob.
The door machine grab bucket control method based on the door machine grab bucket grabbing amount control system comprises the following steps:
Firstly, determining a proper opening angle of a grab bucket corresponding to a material to be grabbed:
the method comprises the steps of 1, rotating a material selection knob to a gear matched with the material, and starting a deep excavation starting button, wherein the deep excavation starting button sends a grabbing signal to a PLC (programmable logic controller), the PLC controls a winch motor driving shaft of a supporting mechanism to continuously rotate forwards until the PLC collects a grab bucket weight value transmitted by an overload system to be 0;
Step 2, grabbing materials at a specified opening angle by the grab bucket, lifting the materials away from the material surface, and judging whether the grabbing reaches the maximum operation capacity of the gantry crane or not according to the grab bucket weight value displayed in real time by the overload system;
Step 3, if the weight value of the grab bucket in the step 2 does not reach or exceed the maximum operation capacity of the gantry crane, adjusting the rotation number of a driving shaft of a winch motor of the opening and closing mechanism by adjusting a deep-excavation adjusting knob so as to finely adjust the appointed opening angle of the grab bucket; simultaneously, the deep digging adjusting knob inputs a specified signal to the PLC, and the PLC controls the winch motor driving shaft of the opening and closing mechanism to rotate forwardly for a specified number of turns according to the specified signal, so that the opening and closing steel wire rope is released to a specified length, and the grab bucket is opened to a new specified opening angle;
Repeating the steps 2-3, wherein the appointed opening angle of the grab bucket meets the condition that the material grabbing amount reaches the maximum operation capacity of the gantry crane;
and (II) completing all material grabbing in an automatic grabbing mode based on the opening angle determined in the step (I):
The deep digging adjusting knob is kept at an optimal adjusting value, and an automatic grabbing starting button is started;
the PLC controller controls the winch motor driving shaft of the supporting mechanism to continuously rotate forwards, meanwhile, the deep-excavation adjusting knob inputs a specified signal to the PLC controller, the PLC controller controls the winch motor driving shaft of the opening and closing mechanism to rotate forwards for a specified number of turns, the specified length of the opening and closing steel wire rope is released downwards, and the grab bucket is opened to a specified opening angle in the descending process;
When the PLC controller obtains that the weight value of the grab bucket detected by the overload system is 0, the PLC controller controls a motor driving shaft of a winch of the opening and closing mechanism to reversely rotate for a specified number of turns, the wire rope is lifted to be tightened and opened to a specified length, the grab bucket is closed, and the material grabbing is completed;
When the PLC collects that the rotating speed input by the speed encoder of the opening and closing mechanism is 0, the PLC controls the winch motor driving shaft of the supporting mechanism to continuously rotate reversely, the supporting steel wire ropes are pulled up, when the numerical value difference transmitted by the displacement sensor of the opening and closing mechanism and the displacement sensor of the supporting mechanism is 0, the rope difference between the two opening and closing steel wire ropes and the two supporting steel wire ropes is 0, the grab bucket leaves the material surface, the grabbing action is completed, and the rotating bucket can be controlled to be transferred to a target position for unloading;
In the processes of the step (one) and the step (two), the PLC calculates whether the rope difference between the supporting steel wire rope and the opening and closing steel wire rope exceeds a set threshold value according to the position signals input by the supporting mechanism position sensor and the opening and closing mechanism position sensor so as to judge whether the rope loosening state of the steel wire rope exists, and when the PLC calculates that the rope difference exceeds the set threshold value, the PLC controls the motor driving shaft rotating speed of the supporting mechanism winch or the motor driving shaft rotating speed of the opening and closing mechanism winch according to the current movement speeds of the supporting steel wire rope and the opening and closing steel wire rope acquired by the supporting mechanism speed encoder and the opening and closing mechanism speed encoder.
Compared with the prior art, the control system and the corresponding control method for the grabbing amount of the door machine grab bucket can effectively improve the operation efficiency of receiving and unloading cargoes with higher specific gravity, avoid damage to the door machine due to overload, ensure the safety of a man-machine, and simultaneously have the advantages of simplicity in operation, reduction in the requirement on the operation level of a door machine driver, reduction in the labor intensity of the driver and objectively reduction in the risk of accidents.
Drawings
FIG. 1 is a schematic diagram of a gantry crane grab grabbing amount control system of the invention;
Fig. 2 is a front view of an operation panel of the door operator grab bucket grabbing amount control system of the present invention.
Detailed Description
The invention will now be further described with reference to the accompanying drawings and specific examples, which are in no way limiting.
The door machine grab bucket grabbing amount control system of the embodiment is suitable for four-rope grab buckets; specifically, the four-rope grab bucket mainly comprises an upper cross beam, a pull rod, a lower cross beam and a bucket part, and is matched with a bridge crane for use so as to grab various bulk cargos and carry out operations such as loading, unloading, turning and the like; the crane lifting system is provided with a front hoisting mechanism and a rear hoisting mechanism, wherein the front hoisting mechanism is simply called an opening and closing mechanism, and the rear hoisting mechanism is simply called a supporting mechanism, the rear hoisting mechanism is composed of a hoisting motor and a set of steel wire rope winding drum system, one ends of two supporting steel wire ropes are led out by steel wire rope winding drums, the other ends of the two supporting steel wire ropes are symmetrically fixed at two ends of a balance beam of a grab bucket to play a supporting role;
The four-rope grab bucket has the operation principle that the front winches synchronously lower the open-close steel wire rope to enable the dead weight of the lower cross beam to force the large shaft of the lower cross beam of the bucket to be opened to a proper angle, the two winches are controlled to synchronously lower the supporting steel wire rope to enable the grab bucket to descend to the position where the grab bucket grabs materials, the opening-closing mechanism is controlled to lift to tighten the open-close steel wire rope to finish grabbing materials, the grab bucket is closed, the closed hopper is filled with materials, then the supporting steel wire rope is controlled to synchronously tighten the supporting steel wire rope to enable the four steel wire ropes to be in a uniform stress state, the two winches are controlled to synchronously operate recently, the grab bucket is lifted to a safe height, and then the grab bucket is moved to a required unloading field to unload materials.
In the process, based on the fact that the grab bucket grabbing amount of each time in the current operation process is different, the problem that the grabbing efficiency is low for materials with high specific gravity is generally solved, and a set of gantry crane grab bucket grabbing amount control system capable of effectively improving the operation efficiency is additionally arranged.
As shown in fig. 1, the door machine grab bucket grabbing amount control system comprises a supporting mechanism position sensor, an opening and closing mechanism position sensor, a supporting mechanism speed encoder, an opening and closing mechanism speed encoder, an operation panel and a PLC controller, wherein,
The supporting mechanism position sensor is arranged on a rotating mechanism of a winch of the supporting mechanism to acquire a rotating position signal of a motor driving shaft of the winch of the supporting mechanism, and further determine the forward or reverse rotation turns of the motor driving shaft so as to obtain the lowering length or tightening length of the supporting steel wire rope;
the opening and closing mechanism position sensor is arranged on a rotating mechanism of a winch of the opening and closing mechanism to acquire a rotating position signal of a motor driving shaft of the winch of the opening and closing mechanism so as to determine the number of positive or negative rotating turns of the motor driving shaft, thereby obtaining the releasing length or the tightening length of the opening and closing steel wire rope;
Specifically, the supporting mechanism position sensor and the opening and closing mechanism position sensor can selectively adopt a Hall sensor which is arranged on the motor rotor assembly and determines a position signal of the rotation of the motor driving shaft according to the self rotation Hall sector value so as to convert the positive rotation number or the reverse rotation number of the motor rotating shaft;
The supporting mechanism speed encoder is arranged on a motor driving shaft of a winch of the supporting mechanism so as to acquire a rotating speed signal of the motor driving shaft of the winch of the supporting mechanism;
the speed encoder of the opening and closing mechanism is arranged on a motor driving shaft of the winch of the opening and closing mechanism so as to detect a rotating speed signal of the motor driving shaft of the winch of the opening and closing mechanism;
A control box is arranged on the side surface of the linkage table in the cab of the door machine, the PLC controller is arranged in the control box, and the operation panel is arranged on the upper surface of the control box;
The PLC is electrically connected with the position sensor of the supporting mechanism to obtain a rotating position signal of a motor driving shaft of a winch of the supporting mechanism, and further obtain the releasing length or the tightening length of the supporting steel wire rope;
the PLC is electrically connected with the displacement sensor of the opening and closing mechanism to obtain a rotating position signal of a motor driving shaft of a winch of the opening and closing mechanism, and further obtain the releasing length or the tightening length of the opening and closing steel wire rope
The PLC is electrically connected with the speed encoder of the supporting mechanism to obtain a rotating speed signal of a motor driving shaft of a winch of the supporting mechanism;
the PLC is electrically connected with the speed encoder of the opening and closing mechanism so as to obtain a rotating speed signal of a motor driving shaft of a winch of the opening and closing mechanism;
The PLC is electrically connected with a winch motor of the supporting mechanism through the frequency converter A so as to control the rotating speed of a winch motor driving shaft of the supporting mechanism through the PLC, and further, when the PLC detects that the supporting steel wire rope is too much in rope loosening caused by rope difference relative to the opening and closing steel wire rope, the PLC controls the lowering speed or the lifting tightening speed of the supporting steel wire rope so as to reduce the rope difference;
the PLC is electrically connected with a winch motor of the opening and closing mechanism through the frequency converter B, so that the rotating speed of a winch motor driving shaft of the opening and closing mechanism is controlled through the PLC, and further when the PLC detects that the opening and closing steel wire rope is too much in rope loosening caused by rope difference relative to the supporting steel wire rope, the lowering speed or the lifting and tightening speed of the opening and closing steel wire rope is controlled, so that the rope difference is reduced;
The PLC is electrically connected with an overload system which is arranged in a matched manner with the grab bucket so as to acquire the grab bucket weight value measured by the overload system;
as shown in fig. 2, the operation panel is provided with a display screen, a material selection knob, a deep-digging adjustment knob, a deep-digging start button and an automatic grabbing start button, specifically,
The material selecting knob is connected with the PLC through a digital quantity input module, and particularly, N gears are arranged on the material selecting knob at intervals in the circumferential direction of the material selecting knob, the number N of the gears is consistent with the number of the material types with different specific gravities, which are handled in actual operation of a company, of each gear corresponds to one type of material, when the material selecting knob rotates to a specified gear, the gears output specified signals to the PLC, so that the PLC controls the forward rotation of a driving shaft of a winch motor of an opening and closing mechanism to rotate for specified turns, the steel wire rope is released to a specified length, and the grab bucket is opened to a specified opening angle according to the known material types;
the appointed opening angle is a proper opening angle determined according to the conventional specific gravity of the materials, but in the actual operation process, the actual specific gravity of the materials is greatly different due to different purities;
In this embodiment, according to the fact that the cargoes mainly loaded and unloaded are Yang Difen, PB powder, FOR powder and Brazil powder, 4 gears are arranged on the material selection knob, and according to the operation experience, four reference adjustment values are set according to the difference of specific gravities of four materials, as shown in the following table 1.
Table 1:
| Goods class | Specific gravity | Reference adjustment value |
| Yang Difen A | 1.9 | 5 |
| PB powder | 2.1 | 4.4 |
| FOR powder | 2.27 | 3.5 |
| Brazil powder | 2.56 | 2.3 |
The deep-excavation adjusting knob is an electrodeless knob and is connected with the PLC through an analog quantity input module to output a specified signal to the PLC, so that the PLC controls the winch motor driving shaft of the opening and closing mechanism to rotate forwards or reversely for specified turns, the opening and closing steel wire rope is released to a specified length or lifted upwards to be tightened to the specified length, the rotation turns of the winch motor driving shaft are adjusted, and the opening angle of the grab bucket is further adjusted, specifically, when the electrodeless knob is set, the grab bucket is rotated for one circle, the corresponding scale range is 0-9, the opening angle (namely the opening angle between two bucket petals) of the corresponding grab bucket is 0-180 degrees, any micro adjustment of the opening angle of the grab bucket can be realized through the electrodeless knob, and the grab bucket is adjusted to a proper opening angle from the specified opening angle, wherein when the corresponding scale value of the deep-excavation adjusting knob is 0, the position of the grab bucket is in neutral position;
The suitable opening angle means that after the grab bucket is used for grabbing and closing materials at the current opening angle, the grabbing amount of the materials in the grab bucket is 40t and is suitable for the maximum work load of the gantry crane, and in addition, for similar cargoes in different batches, the specific gravity value of the similar cargoes has larger deviation which is not suitable for prediction because of the purity problem, so that on the basis of a theoretical adjustment value, a gantry crane driver is required to correspondingly adjust the suitable opening angle of the grab bucket in the grabbing operation process of the actual specific gravity of the current cargoes;
The deep-excavation starting button is electrically connected with the PLC, and outputs an electric signal to the PLC when the deep-excavation starting button is started, so that the PLC controls a motor driving shaft of a winch of a supporting mechanism to rotate to lower a supporting steel wire rope according to a specified signal output by a material selection knob or a deep-excavation adjusting knob, so that a grab bucket is lowered to a material surface to be grabbed, and meanwhile, the PLC controls the motor driving shaft of the winch of an opening and closing mechanism to rotate to lower an opening and closing steel wire rope until the grab bucket is opened to a specified opening angle;
The automatic grabbing start button is connected with the PLC through a data transmission line and is used for starting and closing the automatic grabbing action of the grab bucket, and concretely, when the automatic grabbing start button is started, the PLC controls the winch motor driving shaft of the supporting mechanism to rotate to lower the supporting wire rope so as to gradually lower the grab bucket to the material level to be grabbed, meanwhile, the PLC controls the winch motor driving shaft of the opening and closing mechanism to rotate to lower the opening and closing wire rope until the grab bucket is opened to the position where the current specified regulation value of the deep digging regulation knob corresponds to the specified opening angle;
The display screen is electrically connected with the PLC, and is provided with an upper display frame and a lower display frame, wherein the upper display frame is used for displaying a reference adjusting value corresponding to the current gear of the material selection knob for a door operator driver to reference, and the lower display frame is used for displaying an actual adjusting value corresponding to the current position of the deep excavation adjusting knob.
The automatic grabbing has the advantages that in the operation process of the door machine, the tightness state of the 4 steel wire ropes can be always kept the same as the previous state when the grab bucket descends to the material surface each time, namely, the initial state is the same when the grab bucket grabs goods each time, the follow-up control modes are the same, the grabbing amount is the same, the error of each grabbing amount is reduced, and the stability of the optimal operation efficiency is ensured.
Based on the control system for the grabbing amount of the grab bucket of the gantry crane, the control method for realizing quantitative and efficient grabbing operation on different materials comprises the following specific implementation steps:
The method comprises the steps of (1) determining a suitable opening angle of a grab bucket corresponding to a material to be grabbed by utilizing manual adjustment:
The method comprises the steps that a door operator rotates a material selection knob to a gear matched with a material to be grabbed according to the type of the material, and starts a deep-excavation starting button, wherein the deep-excavation starting button sends grabbing signals to a PLC (programmable logic controller) at the moment, the PLC controls a winch motor driving shaft of a supporting mechanism to continuously rotate forward to lower a supporting steel wire rope, when the PLC collects a grab bucket weight value transmitted by an overload system to be 0, the grab bucket is indicated to be lowered onto the material surface, the PLC controls a winch motor driving shaft of the supporting mechanism to stop rotating, in the process, the material selection knob inputs a specified signal to the PLC, and the PLC controls the winch motor driving shaft of an opening and closing mechanism to rotate forward for a specified number of turns according to the specified signal, so that the grab bucket is opened to a specified opening angle corresponding to the current gear of the material selection knob;
step 2, a driver of the portal crane manually controls a driving shaft of a winch motor of the opening and closing mechanism to reversely rotate, the winch motor lifts up to tighten the opening and closing steel wire rope to a specified length, and the grab bucket returns to a closed state; then, the crane driver manually controls the winch motor driving shaft of the supporting mechanism to reversely rotate, and lifts up the two opening and closing steel wire ropes until the grab bucket leaves the material surface;
Step 3, if the weight value of the grab bucket does not reach or exceed the maximum operation capacity of the gantry crane in the step 2, a gantry crane driver carries out left-hand adjustment or right-hand adjustment on a deep-excavation adjusting knob based on a reference adjusting value displayed by a display screen so as to finely adjust the rotation circle number of a winch motor driving shaft of an opening and closing mechanism and further adjust the appointed release length of an opening and closing steel wire rope;
Repeating the step 2 and the step 3 until the opening angle of the grab bucket reaches a proper opening angle correspondingly according to the adjusting value of the deep-excavation adjusting knob, namely the material grabbing amount of the grab bucket under the opening angle reaches the maximum operation capacity of the door machine;
and (II) keeping the grab bucket open to a proper opening angle every time of grabbing, and completing material grabbing in an automatic grabbing mode:
the deep digging adjusting knob is kept at the optimal adjusting value, and the automatic grabbing starting button is pressed, at the moment, the four actions of descending, opening, closing and ascending of the grab bucket are automatically controlled by the PLC controller, specifically,
The PLC controls the winch motor driving shaft of the supporting mechanism to continuously rotate in the forward direction, so as to lower the supporting steel wire rope, enable the grab bucket to gradually descend to the surface of the object to be grabbed, and simultaneously, controls the winch motor driving shaft of the opening and closing mechanism to rotate in the forward direction for a specified number of turns, and lower the opening and closing steel wire rope for a specified length, so that the grab bucket is opened to a proper opening angle in the descending process;
when the PLC controller acquires that the weight value of the grab bucket detected by the overload system is 0, the grab bucket is indicated to be lowered onto the material surface, and at the moment, the PLC controller controls a motor driving shaft of a winch of the opening and closing mechanism to reversely rotate for a specified number of turns, so that the wire rope is lifted up and closed to a specified length, the grab bucket is completely closed, and the material grabbing is completed;
The PLC controls a winch motor driving shaft of the supporting mechanism to continuously rotate reversely, the supporting steel wire ropes are lifted up, when the numerical value difference transmitted by the opening and closing mechanism displacement sensor and the supporting mechanism displacement sensor is 0, the rope difference between the two opening and closing steel wire ropes and the two supporting steel wire ropes is 0, and at the moment, the grab bucket is lifted up to the safe height, and the grabbing action is completed;
And then the grab bucket is manually operated by a door operator to transport and grab the material to the appointed destination position.
In the processes of the step (one) and the step (two), the PLC calculates whether the rope difference between the supporting steel wire rope and the opening and closing steel wire rope exceeds a set threshold value according to the position signals input by the supporting mechanism position sensor and the opening and closing mechanism position sensor so as to judge whether the rope loosening state of the steel wire rope exists, and when the PLC calculates that the rope difference exceeds the set threshold value, the PLC controls the motor driving shaft rotating speed of the supporting mechanism winch or the motor driving shaft rotating speed of the opening and closing mechanism winch according to the current movement speeds of the supporting steel wire rope and the opening and closing steel wire rope acquired by the supporting mechanism speed encoder and the opening and closing mechanism speed encoder.
The grab bucket grabbing amount control system of the gantry crane is firstly installed on a 15# gantry crane of an applicant operation cargo yard and performs material grabbing operation test operation. During the test run, the operation efficiency of the 15# gantry crane with the gantry crane grab grabbing amount control system is compared with the average operation efficiency of the 12# to 16# gantry cranes without the gantry crane grab amount control system, and specific test results are shown in the following table 2.
Table 2:
From the comparison data results in table 2, it is seen that in the operation process of the six gantry cranes for operating the same cargo class of the same ship, the operation efficiency of the 15# gantry crane is obviously improved compared with the average operation efficiency of the other five gantry cranes, and the highest efficiency improvement rate can reach 16.70%.
Meanwhile, in the process of test operation, the single-person operation efficiency of six drivers (abbreviated as drivers A-F) specialized in the 15# gantry crane in the operation process after the gantry crane grab grabbing amount control system is installed and the average operation efficiency of all drivers of the cargo yard 12# -16# gantry crane are counted, and specific statistical results are shown in the following tables 3-8.
TABLE 3 statistics of driver A operating efficiency
TABLE 4 statistics of driver B operating efficiency
TABLE 5 statistics of driver C operating efficiency
TABLE 6 statistics of driver D operating efficiency
TABLE 7 statistics of driver E operating efficiency
TABLE 8 statistics of driver F operating efficiency
As can be seen from the statistics of the single operator efficiency data counted in the tables 3-8, compared with the average operator efficiency of all drivers driving the 12# to 16# door machines, the single operator efficiency of the door machine drivers is improved, and the highest efficiency improvement amplitude reaches 15.96 percent
In addition, the door operator grab bucket grabbing amount control system is used for analyzing from the economic angle of an applicant enterprise. From the perspective of saving the grab bucket and realizing the economic value, if the applicant carries out such reconstruction on ten gantry cranes which are used for carrying out bulk cargo operation frequently, the storage of the grab bucket is reduced, and according to the calculation of reducing one grab bucket, each grab bucket is 20 ten thousand yuan, and about 12 grab buckets (10 common and 2 standby) are needed for 10 gantry cranes, so that the cost can be saved by 240 ten thousand yuan. In view of improving the working efficiency and realizing the economic value, if the working capacity is calculated by improving the working capacity by 6%, the working capacity can be improved by 30 ten thousand tons by 10 gantry cranes. The profit per ton is calculated according to 8 yuan, and the economic benefit can be created in one year as 30 multiplied by 8=240 ten thousand yuan.
Claims (3)
1. A door machine grab bucket control method based on a door machine grab bucket grabbing amount control system is characterized in that the door machine grab bucket grabbing amount control system comprises a) a supporting mechanism position sensor, a control mechanism and a control mechanism, wherein the supporting mechanism position sensor is arranged on a rotating mechanism of a winch of a supporting mechanism so as to acquire a rotating position signal of a motor driving shaft of the winch of the supporting mechanism; B) an opening and closing mechanism position sensor installed on a rotating mechanism of a hoist of the opening and closing mechanism to collect a rotational position signal of a motor drive shaft of the hoist of the opening and closing mechanism, c) a supporting mechanism speed encoder installed on a motor drive shaft of the hoist of the supporting mechanism to collect a rotational speed signal of a motor drive shaft of the hoist of the supporting mechanism, d) an opening and closing mechanism speed encoder installed on a motor drive shaft of the hoist of the opening and closing mechanism to detect a rotational speed signal of a motor drive shaft of the hoist of the opening and closing mechanism, e) a PLC controller provided in a control box installed in a side of a linkage table in a cab of a door machine, the PLC controller being electrically connected to the supporting mechanism position sensor and the opening and closing mechanism displacement sensor, respectively, the PLC controller being electrically connected to the supporting mechanism speed encoder and the opening and closing mechanism speed encoder, respectively, the PLC controller being electrically connected to a hoist of the supporting mechanism through a frequency converter B, the PLC controller being electrically connected to a system installed in an overload support with a grab, and f) an operation panel provided on an upper surface of the control box, the operation panel being electrically connected to a material selecting knob through a digital display, a material selecting knob, and a material selecting module being electrically connected to the PLC The deep digging adjusting knob is connected with the PLC through the analog quantity input module, and is electrically connected with the PLC and is provided with an automatic grabbing start button;
The door machine grab bucket control method comprises the following steps:
Firstly, determining a proper opening angle of a grab bucket corresponding to a material to be grabbed:
the method comprises the steps of 1, rotating a material selection knob to a gear matched with the material, and starting a deep excavation starting button, wherein the deep excavation starting button sends a grabbing signal to a PLC (programmable logic controller), the PLC controls a winch motor driving shaft of a supporting mechanism to continuously rotate forwards until the PLC collects a grab bucket weight value transmitted by an overload system to be 0;
Step 2, grabbing materials at a specified opening angle by the grab bucket, lifting the materials away from the material surface, and judging whether the grabbing reaches the maximum operation capacity of the gantry crane or not according to the grab bucket weight value displayed in real time by the overload system;
Step 3, if the weight value of the grab bucket in the step 2 does not reach or exceed the maximum operation capacity of the gantry crane, adjusting the rotation number of a driving shaft of a winch motor of the opening and closing mechanism by adjusting a deep-excavation adjusting knob so as to finely adjust the appointed opening angle of the grab bucket; simultaneously, the deep digging adjusting knob inputs a specified signal to the PLC, and the PLC controls the winch motor driving shaft of the opening and closing mechanism to rotate forwardly for a specified number of turns according to the specified signal, so that the opening and closing steel wire rope is released to a specified length, and the grab bucket is opened to a new specified opening angle;
Repeating the steps 2-3 until the appointed opening angle of the grab bucket meets the condition that the material grabbing amount reaches the maximum operation capacity of the gantry crane, wherein the appointed opening angle of the current grab bucket is a proper opening angle of the grab bucket;
and (II) completing all material grabbing in an automatic grabbing manner based on the proper opening angle determined in the step (I):
The deep digging adjusting knob is kept at an optimal adjusting value, and an automatic grabbing starting button is started;
The PLC controller controls the winch motor driving shaft of the supporting mechanism to continuously rotate forwards, meanwhile, the deep-excavation adjusting knob inputs a specified signal to the PLC controller, the PLC controller controls the winch motor driving shaft of the opening and closing mechanism to rotate forwards for a specified number of turns, the specified length of the opening and closing steel wire rope is released downwards, and the grab bucket is opened to a proper opening angle in the descending process;
When the PLC controller obtains that the weight value of the grab bucket detected by the overload system is 0, the PLC controller controls a motor driving shaft of a winch of the opening and closing mechanism to reversely rotate for a specified number of turns, the wire rope is lifted to be tightened and opened to a specified length, the grab bucket is closed, and the material grabbing is completed;
When the PLC collects that the rotating speed input by the speed encoder of the opening and closing mechanism is 0, the PLC controls the winch motor driving shaft of the supporting mechanism to continuously rotate reversely, the supporting steel wire ropes are pulled up, when the numerical value difference transmitted by the displacement sensor of the opening and closing mechanism and the displacement sensor of the supporting mechanism is 0, the rope difference between the two opening and closing steel wire ropes and the two supporting steel wire ropes is 0, the grab bucket leaves the material surface, the grabbing action is completed, and the rotating bucket is controlled to be transferred to a target position for unloading;
In the processes of the step (one) and the step (two), the PLC calculates whether the rope difference between the supporting steel wire rope and the opening and closing steel wire rope exceeds a set threshold value according to the position signals input by the supporting mechanism position sensor and the opening and closing mechanism position sensor so as to judge whether the rope loosening state of the steel wire rope exists, and when the PLC calculates that the rope difference exceeds the set threshold value, the PLC controls the adjustment of the rotating speed of a motor driving shaft of the supporting mechanism winch or the rotating speed of the motor driving shaft of the opening and closing mechanism winch according to the current moving speeds of the supporting steel wire rope and the opening and closing steel wire rope acquired by the supporting mechanism speed encoder and the opening and closing mechanism speed encoder.
2. The method for controlling the grab bucket of the gantry crane based on the grab bucket grabbing amount control system of the gantry crane according to claim 1, wherein the position sensor of the supporting mechanism and the position sensor of the opening and closing mechanism are hall sensors, which are installed on the rotor assembly of the motor.
3. The method for controlling the grab bucket of the gantry crane based on the grab bucket grabbing quantity control system of the gantry crane, which is realized by the control system of the grab bucket of the gantry crane, is characterized in that an upper display frame and a lower display frame are arranged on a display screen, the upper display frame is used for displaying a corresponding value of a current gear of a material selection knob, and the lower display frame is used for displaying a corresponding value of a current position of a deep excavation adjusting knob.
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| CN104401877A (en) * | 2014-10-21 | 2015-03-11 | 武汉理工大学 | Four-rope grab bucket full-automatic operation monitoring and control system and synchronous control method thereof |
| CN216471801U (en) * | 2021-12-30 | 2022-05-10 | 天津港汇盛码头有限公司 | Gantry crane grab bucket grabbing amount control system |
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| JP6259712B2 (en) * | 2014-05-13 | 2018-01-10 | Ｉｈｉ運搬機械株式会社 | Grab bucket unloader operation support device |
| CN108792954B (en) * | 2018-07-30 | 2019-10-25 | 唐山曹妃甸实业港务有限公司 | Bridge type ship unloader grabs amount control method |
| CN109809293B (en) * | 2019-02-12 | 2020-06-16 | 南通润邦重机有限公司 | Intelligent grabbing method of mechanical grab bucket |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104401877A (en) * | 2014-10-21 | 2015-03-11 | 武汉理工大学 | Four-rope grab bucket full-automatic operation monitoring and control system and synchronous control method thereof |
| CN216471801U (en) * | 2021-12-30 | 2022-05-10 | 天津港汇盛码头有限公司 | Gantry crane grab bucket grabbing amount control system |
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