Kinocranes Remote Monitoring Technology for Intelligent Overhead Crane,Gantry Cranes

近年来，

起重机的远程监控技术发展迅速。

通过工业网络技术，

采集起重机

的各种电控系统的信号或信息，实现起重机电控系统的全面计算机图形化监控、

故障监控和跟踪，

对起重机的运行状态、

工作内容的监控和工作量的统计，

有效

提高生产管理水平；

通过远程服务和远程监控手段，

可以实现快速服务响应，

极

大提高设备故障排除时间，保障设备完好率。

随着起重机的发展，

性能和功能的提升，

国家对起重机等特种设备的安全性

的要求越来越重视，使得控制线路逐渐增多、日益复杂，给制造、维护保养以及

维修都提出更高的要求；随着电缆价格日益攀升，

生产成本和使用成本也在大

幅度的提高，

不符合国家节能减排的政策，

由于起重机的工作特性，

小车拖缆在

工作中，每天成百上千次的不停的折叠、伸张，极易造成电缆保护套开裂，断线

等问题，极易造成事故。

二、技术特征

本控制系统目前主要用于各种起在重机上、其包含控制单元和执行单元。

控制单元采用国内外先进的光电无接触式摇杆发动控制信号经过中央芯片

处理由

RS485

总线通讯或

ZigBee

无线通信传输给执行单元。

执行单元接收控制单元传输的数据融合各传感器、

限位等传输来的数据通过

中央处理器运算协调给无触点式固态继电器发送指令完成整个控制回路。

三、创新性、先进性、适用性

1.

集成化控制线路：

采用工业级高性能

CPU

处理处理器加载通讯单元、

采集单元、

储存单元、

控制单元、

反馈单元等组成的集成板块有效的解决了以往大量控制线

路错综繁杂的现象，安装简单、省力、省材。

2.

弱电控制强电：采用

DC5V

弱电压控制

AC380V

强电，控制方便、安全。

3.

数字通讯控制：采用

RS485

总线通讯和

ZigBee

无线通讯技术使控制系统组网

方便、加密性能高。能完成

254

台智能化起重机组网控制。

4.GPRS

通讯：实现远程控制及远程数据采集。

5.

光电式无接触摇杆：减少机械磨损、增加使用寿命。

6.

电流过零点自动分断技术：

为了避免电机分断时，

电机的过电压和对交流接触

In recent years, the remote monitoring technology of cranes has developed rapidly. Through the industrial network technology, a variety of electronic control system of the crane or information signal acquisition, control system of crane comprehensive computer graphical monitoring, fault monitoring and tracking, statistical operation status, the work content of crane monitoring and workload, effectively improve the management level of production; through the remote service and remote monitoring means, can be achieved rapid response services, greatly improve the equipment troubleshooting time, ensure the equipment intact rate. With the development of the crane, the function and performance improvement, safety state of the crane and other special equipment required more and more attention, making the control line gradually increased, to become more complex, manufacturing, maintenance and maintenance are put forward higher requirements; with cable prices rising production cost and use cost greatly the increase does not meet the national energy saving policy, due to the operation characteristics of the crane, car towing at work, hundreds of times a day to keep folding, stretching, extremely easy to cause the cable sheath crack, breakage, extremely easy to cause the accident. Two, the technical characteristics of this control system is mainly used in a variety of lifting machine, including the control unit and the execution unit. The control unit adopts the advanced photoelectric contactless rocker control signal at home and abroad. After the central chip processing, the control unit is transmitted to the execution unit by RS485 bus communication or ZigBee wireless communication. The execution unit receives the data transmitted by the control unit, integrates the data transmitted by the sensors, the limit, etc., and coordinates the operation of the central processor to send instructions to the contactless solid state relay to complete the whole control loop. Three, innovative, advanced and applicable 1. integrated control circuit with integrated plate industrial high performance CPU processor load communication unit, a storage unit, a control unit and a feedback unit, which effectively solves the large complex control circuit of complicated phenomenon, simple installation, labor saving, material. 2. weak current control strong electricity: use DC5V weak voltage to control AC380V strong electricity, convenient and safe control. 3. digital communication control: using RS485 bus communication and ZigBee wireless communication technology to make the control system easy to network and high encryption performance. Can complete 254 sets of intelligent crane network control. 4.GPRS communication: remote control and remote data acquisition. 5. photoelectric contactless rocker: reduce mechanical wear and increase service life. 6. current zero crossing automatic breaking technology: in order to avoid breaking the motor, the motor over-voltage and AC contact

The contact arc ignition, the system adopts three-phase separation technology to maintain, R & D AC current zero load removal technology, make the crane balance stop, which greatly extend the life of the contact point, and it can automatically capture the current AC zero crossing, make contact zero off current, fundamentally eliminate the tension arc contact. 7. start smoothly and reduce the impact function: the automatic input system of motor rotor current limiting resistance when starting, the motor starting smoothly, start automatically after the resection of the rotor current limiting resistor, the normal operation of the crane, greatly reduce the starting current of the crane, the crane to start smoothly, reduce the impact. 8. energy saving and emission reduction, zero start, zero shutdown, easy installation, good maintenance: intelligent crane control system integrates measurement, control, protection, communication, separation of AC contactor as an integrated template. The system uses embedded intelligent technology, bus control technology, so that the crane start stop control, state control, stroke control automatic coordination. The system has the advantages of small size, strong function, zero start, zero shutdown, energy saving and emission reduction. The general electrician can be installed, debugged and maintained correctly. Four, technical advantage RS-485 adopts half duplex operation mode to support multi-point data communication. RS-485 bus network topology usually adopts terminal matching bus type structure. That is, a bus is used to connect all the nodes together, which does not support the ring or star network. RS-485 uses balanced transmission and differential reception, so it has the ability to suppress common mode interference. In addition, the bus transceiver has high sensitivity and can detect the voltage as low as 200mV, so the transmission signal can be recovered beyond kilometer. Some RS-485 transceivers modify the input impedance to allow more than 8 times the number of nodes to connect to the same bus. The RS-485 bus has high communication rate, long transmission distance, high resistance to electromagnetic interference, has sent reliable error handling and error detection mechanism, the destruction of information automatic retransmission characteristics. The old control system compared with the traditional five digital intelligent crane crane control mode to the mode of centralized control, all power cables and control cables, must control box and operation console through the power control center. A large number of cables, not only wiring complex, but also prone to failure. Digital intelligent crane control system uses the fieldbus and wireless control mode, the power cable of the whole crane is greatly reduced, only need to control the twisted pair can be completed, thus greatly improve the reliability, reduce the cost, save more than 80% cable materials such as those of the old crane. It's easy to maintain. The traditional control system uses the old contactor and other switches to form the electrical control mode. When the contactor is working, it is easy to produce arc. When the arc occurs, the huge energy is released in a very short time. Metal elements vaporize and cause high temperature steam and metal to expand rapidly. Rapid and thermal expansion of air and metal vapors can cause huge amounts of air and metal

Metal elements vaporize and cause high temperature steam and metal to expand rapidly. Rapid and thermal expansion of air and metal vapors can cause loud explosions and tremendous pressure. The positive and negative switching circuit of motor is complex, difficult to install and easy to damage. At the same time, the power system also produces large harmonic and pollution, which damages the other equipment in the power grid. Digital intelligent control system to achieve the dream of power control system for low power consumption, no spark, simple control circuit, a fundamental solution to the relevant problems in the crane control and operation, greatly prolongs the life of the control system, can improve the energy efficiency, the service life is ten times the old crane control system