Application Case of Intelligent Crane: Application of Automatic Unmanned Crane in Stripping Workshop

Project introduction: The following model diagram shows the design and manufacturing tasks of the intelligent overhead traveling crane project of the slitting workshop between Taiguan Company and Shenzhen Kangyi Industrial Co., Ltd., including the intelligent Overhead crane and automatic lifting appliance, automatic operation system program and program control electrical integration, and a total of two sets of intelligent overhead traveling cranes for storage and automatic loading and unloading production lines.
This project aims to solve the production situation of high workload, low efficiency, and harsh working environment, improve production capacity, reduce losses, and achieve industrial intelligent upgrading.

Utilize automatic control technology to achieve the positioning of the crane's travel and the loading and unloading of the hook, and monitor the entire site in the control room. Utilize the anti swing algorithm of the frequency converter anti swing module to achieve hook swing control of the crown block.

The upper MES system is responsible for scheduling and database management of multiple overhead cranes on site. The crown block control system provides real-time feedback on the three-dimensional spatial coordinates of the hook during operation through AMS sensors, and provides feedback on the completion results after loading and unloading.

The six main frameworks of automatic unmanned intelligent cranes include intelligent overhead crane control system, regional security system, on-site monitoring system, MES system interface, manual/automatic control system, and three-dimensional coordinate system.

The overhead crane control system can freely plan a three-dimensional walking route in teaching mode to avoid obstacles. When the automatic control system of the overhead crane malfunctions, it can be switched to manual operation to complete the lifting.

Control room function: Real time monitoring and management of all overhead cranes in a single area, downloading production operation content for data statistics. The control room can only be viewed and has no authority to modify or operate the on-site crane.

The fully automatic function of intelligent cranes mainly consists of the following functions:

(1) Automatic material grabbing, loading, and unloading

Grasping, loading and unloading, and stacking are the basic operations and regular functions of intelligent cranes. The fully automatic function ensures that the efficiency of the intelligent crane is not lower than that of normal manual operations, and the fully automatic control input rate is ≥ 90%. (i.e., if the fully automatic operation time is calculated based on 8 hours per team, it should not be less than 7.2 hours)

(2) Is the automatic material waiting and loading/unloading area idle

When the intelligent crane automatically grabs or loads and unloads materials, it should have the function of automatic detection by the material platform, which can detect the status of materials in real-time and avoid empty grabbing or stacking situations.

(3) Automatically determine the timing of material grabbing and loading

The fully automatic control of intelligent cranes should determine the timing of material grabbing and loading and unloading based on production priority, and queue up the received tasks for processing.

(4) Safety protection and interlocking under fully automatic working conditions

The principle of intelligent cranes operating within the same span of the workshop is one for use and one for backup. To ensure that accidents do not occur during normal operation, they must have complete interlocking protection functions, collision protection between the two cranes, limit protection between the intelligent crane and the surrounding walls, and limit protection for the large and small cars of the intelligent crane. In addition, the original protection function of the intelligent crane needs to be preserved and continued to be used.

(5) Emergency response function for emergencies under fully automatic working conditions. The fully automatic control of intelligent cranes should have a complete protection mechanism. For some emergencies, such as material collapse, severe tilting of lifting appliances, and rotation of steel wire ropes, there should be emergency response and alarm functions.

(6) The optimization of anti shaking function of intelligent cranes adopts a closed-loop anti shaking technology with energy crown. It is planned to adopt an integrated optimization method of physical anti shaking and virtual mathematical model anti shaking, which complement each other to achieve the goal of simplicity and practicality, thereby ensuring safety.

(7) The function of identifying personnel when the crane is moving is based on the premise of putting people first and safety first. This project plans to establish an infrared personnel identification system, which will install safety grilles to divide the area outside the normal working and moving area of the crane. At the same time, infrared cameras will be installed to identify personnel entering the dangerous area, achieving the automation and safety of the entire transportation process.