CN-121974256-A - Bridge crane electromagnetic chuck misoperation prevention protection control method and system

CN121974256ACN 121974256 ACN121974256 ACN 121974256ACN-121974256-A

Abstract

The invention relates to the technical field of cranes, in particular to a bridge crane electromagnetic chuck misoperation prevention protection control method and system. The method comprises the steps of S1, synchronously collecting magnetic force, personnel existence and distance, operator identity and double-channel instruction data, S2, calculating a magnetic force safety coefficient, alarming and prohibiting lifting when the magnetic force safety coefficient is lower than a safety threshold, S3, calculating personnel intrusion risk indexes, alarming and prohibiting release and emergency braking when the risk threshold is exceeded, S4, verifying operator identity authority and verifying double-channel instruction consistency, alarming and prohibiting action when the double-channel instruction consistency is failed, S5, calculating an environment dynamic stability coefficient, further fusing and calculating a comprehensive safety index to generate risk early warning, S6, carrying out logic arbitration on various safety events according to preset priority, executing conflict-free protection action and recording whole flow data. The invention realizes quantitative evaluation, multi-level early warning and intelligent arbitration of safety risk, and remarkably improves the intrinsic safety level and system reliability of operation.

Inventors

YAO XUEFENG
LIANG DONG
TENG RONGRONG
ZHU LIYANG
LIU YANG
LIU WUSHENG

Assignees

江苏省特种设备安全监督检验研究院

Dates

Publication Date: 20260505
Application Date: 20260211

Claims (10)

1. The anti-misoperation protection control method for the electromagnetic chuck of the bridge crane is characterized by comprising the following steps of: s1, acquiring magnetic force data of an electromagnetic chuck in real time, scanning personnel in a lifting area to acquire personnel presence and distance data, and acquiring operator identity data and double-channel operation instruction data; S2, calculating a magnetic safety coefficient based on magnetic data, and judging whether the magnetic safety coefficient is lower than a safety threshold value to generate a magnetic insufficiency alarm and a lifting prohibition instruction; S3, calculating a personnel intrusion risk index based on the personnel existence and distance data, and judging whether the personnel intrusion risk index exceeds a risk threshold value to generate personnel intrusion alarm and release prohibition and emergency braking instructions; S4, verifying the identity authority of an operator and checking the consistency of the two-channel operation instruction, and generating an alarm and forbidden action instruction if the checking fails; S5, calculating an environment dynamic stability coefficient based on personnel activity intensity and operation instruction fluctuation, fusing a magnetic force safety coefficient and a personnel invasion risk index, and calculating a comprehensive safety index to generate an overall risk early warning; and S6, carrying out logic arbitration on various security events according to preset priority, executing final conflict-free protection action, and recording full-flow data for analysis and optimization.
2. The bridge crane electromagnetic chuck malfunction prevention protection control method according to claim 1, wherein in step S1, the process of acquiring each data specifically comprises: determining the boundary of a space area covered by the current lifting operation of the crane; acquiring a real-time magnetic induction intensity value of a working surface of the electromagnetic chuck at a fixed sampling frequency; Scanning a person in a lifting area, acquiring a binary state signal indicating whether a person exists in the area, and synchronously acquiring the minimum horizontal projection distance between the outline of the person and the center point of a lifting target; before the system is ready to respond to the request of adsorption or release operation, the individual identification code of the current request execution operation is obtained through an identification verification function; And synchronously receiving and analyzing an operation instruction code from the high-altitude driving position control terminal and a confirmation instruction code from the ground command position control terminal, wherein the operation instruction code and the confirmation instruction code are elements in a predefined instruction set.
3. The method for protecting and controlling the misoperation prevention of the electromagnetic chuck of the bridge crane according to claim 1, wherein in the step S2, the magnetic force safety coefficient is calculated and judged specifically as follows: invoking a safe magnetic force threshold Msafe corresponding to the type and the quality of the current lifted material from the system configuration parameters; calculating a real-time magnetic force safety coefficient km=m/Msafe; wherein M is a real-time magnetic induction intensity value; If Km < Kth is continuously over the set debounce time Td, the magnetic force is judged to be in a 'magnetic force shortage' state, an audible and visual alarm is triggered, and a logic locking signal for prohibiting the electromagnetic chuck from executing lifting action is output.
4. The method for protecting and controlling the electromagnetic chuck of the bridge crane against misoperation according to claim 1, wherein in the step S3, the risk index of personnel intrusion is calculated and judged specifically as follows: Setting a personnel safety distance threshold D0 and a risk change sensitivity coefficient k; acquiring a personnel presence signal P, and if the personnel presence is 1 and the personnel absence is 0 in the lifting area; Acquiring a personnel distance D; Calculating a personnel invasion risk index r=p·1/[1+exp (k· (D-D0)) ]; And setting a high risk judging threshold Rth, judging that personnel invades high risk when R > Rth, triggering the highest-level audible and visual alarm, outputting a hard logic lock instruction for prohibiting the electromagnetic chuck from executing release action, and triggering an emergency braking instruction of a crane running mechanism.
5. The bridge crane electromagnetic chuck malfunction protection control method according to claim 1, wherein in step S4, the consistency of the verification authority and the verification instruction is specifically: Comparing the obtained operator identification code with an operator database which is prestored in the system and authorized, and verifying whether the identification code exists or not and whether the level of the associated operation authority is not lower than the level of executing the current requested operation or not; for key operation instructions including adsorption and release, checking whether the instructions from the cab are completely consistent with the confirmation instructions from the ground or not, and all the instructions belong to an effective instruction set.
6. The bridge crane electromagnetic chuck malfunction protection control method according to claim 1, wherein in step S5, the calculated comprehensive safety index is specifically: Setting a backtracking time window Tw for analyzing a sequence of personnel presence signals, calculating the state jump times Nch of the personnel presence signals in the window, and simultaneously calculating the standard deviation sigma of all distances recorded when personnel exist in a scanning area in the window; calculating a person activity fluctuation factor fp=tanh (Nch/a+σ/b); Meanwhile, analyzing an effective operation instruction sequence from a cab in the window, and calculating the times Ncm of the change of the instruction type; Calculating an operation instruction fluctuation factor fc=tanh (Ncm/c); In the formula, a, b and c are normalization constants, and tan h is a hyperbolic tangent function; calculating an environmental dynamic stability factor es=1-max (Fp, fc); calculating the integrated safety index is=ωm·km+ωp· (1-min (R, 1)) +ωe·es; wherein ωm, ωp, ωe are weight coefficients, ωm+ωp+ωe=1, km is a magnetic force safety coefficient calculated in step S2, and R is a personnel invasion risk index calculated in step S3.
7. The bridge crane electromagnetic chuck malfunction protection control method according to claim 1, wherein in step S6, the logic arbitration of the multiple security events is specifically: Defining fixed processing priorities for the four abnormal events generated in the steps S2, S3, S4 and S5, wherein the priorities are sequentially from high to low, namely, the abnormal event generated in the step S3, the abnormal event generated in the step S2, the abnormal event generated in the step S4 and the abnormal event generated in the step S5; And scanning the state register of the event with a fixed period, and when the occurrence of the abnormal event is identified, executing only the preset protection action combination corresponding to the abnormal event with the highest priority in all the current abnormal events.
8. The method for protecting and controlling the misoperation prevention of the electromagnetic chuck of the bridge crane according to claim 7, wherein in the step S6, the whole flow data record specifically comprises: The system establishes a continuous data record stream; And recording a structured log in each processing period or each time the event state changes, wherein the structured log comprises a time stamp, data generated in the steps S2-S5, the event state and an output instruction field.
9. The bridge crane electromagnetic chuck malfunction protection control method according to claim 1, wherein when the system is started, an initialization procedure is performed: And loading all preset parameters, establishing logic communication links with all data sources and control targets, and executing one-time complete self-checking, wherein the self-checking content comprises the steps of verifying that each internal computing module is ready and confirming that the key data link is unblocked.
10. The anti-misoperation protection control system for the electromagnetic chuck of the bridge crane is characterized by comprising a central control unit, a data acquisition module, an audible and visual alarm module and a crane executing mechanism; The central control unit comprises a memory and a processor, wherein the memory is used for storing program instructions and a parameter database, and the processor is used for running the program instructions and executing the steps of the bridge crane electromagnetic chuck misoperation prevention protection control method according to any one of claims 1-9.

Description

Bridge crane electromagnetic chuck misoperation prevention protection control method and system Technical Field The invention relates to the technical field of cranes, in particular to a bridge crane electromagnetic chuck misoperation prevention protection control method and system. Background The bridge crane electromagnetic chuck is widely applied to the lifting of magnetic materials in the fields of steel, manufacturing industry and the like. The traditional control system mainly depends on experience of operators and basic interlocking, has obvious potential safety hazards, adopts periodic manual inspection or single threshold value alarm for magnetic force monitoring, cannot sense dynamic attenuation of adsorption force in real time, causes heavy object falling easily due to sudden loss of magnetic force, is passive for personnel protection, has limited visual field of a driver, is difficult to find personnel intrusion in a lifting area in time, cannot actively intervene before dangerous actions in the prior art, is single in operation verification, generally depends on single instructions of the driver, lacks a cooperative confirmation mechanism of a ground command end, is easy to cause misoperation due to false touch or interference, is isolated in risk judgment, is mostly based on a single signal threshold value, lacks comprehensive evaluation and fusion early warning of multiple factors such as magnetic force, personnel, operation compliance and environmental dynamics, and the like, and lacks an explicit priority arbitration mechanism when multiple anomalies occur simultaneously, can cause control instruction conflict, so that the system response is uncertain. Therefore, there is a need for a control method that can comprehensively evaluate risk in real time and perform multi-level security protection intelligently and without collision. Disclosure of Invention The invention provides a bridge crane electromagnetic chuck misoperation prevention protection control method and system, which are used for constructing a quantitative risk model by fusing multisource real-time safety data and executing conflict-free protection actions based on priority arbitration logic, aiming at solving the misoperation risks caused by magnetic attenuation, personnel intrusion, misoperation and environmental interference, comprehensively improving the intrinsic safety level and intelligent management and control capability of the electromagnetic chuck lifting operation and effectively solving the problems in the background technology. The invention provides a bridge crane electromagnetic chuck misoperation prevention protection control method, which comprises the following steps: s1, acquiring magnetic force data of an electromagnetic chuck in real time, scanning personnel in a lifting area to acquire personnel presence and distance data, and acquiring operator identity data and double-channel operation instruction data; S2, calculating a magnetic safety coefficient based on magnetic data, and judging whether the magnetic safety coefficient is lower than a safety threshold value to generate a magnetic insufficiency alarm and a lifting prohibition instruction; S3, calculating a personnel intrusion risk index based on the personnel existence and distance data, and judging whether the personnel intrusion risk index exceeds a risk threshold value to generate personnel intrusion alarm and release prohibition and emergency braking instructions; S4, verifying the identity authority of an operator and checking the consistency of the two-channel operation instruction, and generating an alarm and forbidden action instruction if the checking fails; S5, calculating an environment dynamic stability coefficient based on personnel activity intensity and operation instruction fluctuation, fusing a magnetic force safety coefficient and a personnel invasion risk index, and calculating a comprehensive safety index to generate an overall risk early warning; and S6, carrying out logic arbitration on various security events according to preset priority, executing final conflict-free protection action, and recording full-flow data for analysis and optimization. Further, in step S1, the process of acquiring each data specifically includes: determining the boundary of a space area covered by the current lifting operation of the crane; acquiring a real-time magnetic induction intensity value of a working surface of the electromagnetic chuck at a fixed sampling frequency; Scanning a person in a lifting area, acquiring a binary state signal indicating whether a person exists in the area, and synchronously acquiring the minimum horizontal projection distance between the outline of the person and the center point of a lifting target; before the system is ready to respond to the request of adsorption or release operation, the individual identification code of the current request execution operation is obtained through an identification verification fu