Key Technologies of Intelligent Overhead Cranes

Intelligent cranes can not only automatically complete handling tasks but also achieve higher efficiency and safety.

01:20 16 August 2024

With the rapid development of industrial automation and intelligence, intelligent cranes, as essential equipment in modern industry, are gradually transitioning towards greater intelligence. Intelligent cranes can not only automatically complete handling tasks but also achieve higher efficiency and safety through intelligent control, remote management, and big data analysis. This article discusses several key technologies of intelligent cranes in detail.

1. Safety Monitoring and Remote Service Technology

Safety monitoring and remote service technology are among the core aspects of intelligent cranes. By monitoring the crane's operating status in real-time, faults can be detected and addressed promptly, significantly enhancing the equipment's safety and reliability. This technology encompasses various aspects, including fault monitoring, remote fault diagnosis, data collection, and processing.

During the operation of the crane, the safety monitoring system can record various parameters of the equipment, such as load, operating speed, and hook position, and upload this data to a remote server. Through big data analysis, this data can assist maintenance personnel in troubleshooting and provide valuable insights for the design and optimization of cranes. The application of this technology not only improves the operating efficiency of the equipment but also enables the possibility of remote maintenance and upgrades for cranes.

2. Cargo Information Identification, Verification, and Feedback Technology

Cargo information identification technology is the foundation for realizing automated handling with intelligent cranes. This technology involves multiple stages, including the encoding, collection, identification, transmission, and reading of item information data. In practical applications, different types of cargo (such as steel coils, containers, bundled materials, etc.) require different identification methods.

Commonly used identification technologies include barcode recognition, RFID (Radio Frequency Identification) tags, and image recognition technology. These technologies enable intelligent cranes to accurately identify the type, location, and status of cargo, thereby achieving efficient automated handling. Once the information is identified and verified, it is fed back into the control system, providing data support for the automated operation of intelligent cranes.

3. Anti-Sway Technology for Hoisting Equipment

In automated production, precise control of the crane's hook position is highly demanded. However, during crane operation, the hook may experience significant swinging due to factors such as the acceleration and deceleration of the translation mechanism. This swinging can hinder the precise positioning of loads during loading and unloading, posing safety risks in production. Therefore, research into anti-sway technology for overhead cranes is crucial for improving production efficiency and enhancing the automation and intelligence levels of crane operations.

In engineering applications, overhead crane anti-sway technology mainly includes three types: variable frequency anti-sway technology with swing angle feedback devices, variable frequency speed control anti-sway technology based on swing angle control algorithms, and variable frequency anti-sway technology relying on speed control algorithms. These technologies rely on dedicated variable frequency anti-sway cards to achieve speed control and anti-sway functions. To meet the demand for crane anti-sway, internationally renowned crane equipment suppliers have developed overhead cranes equipped with anti-sway functionality. Some variable frequency drive suppliers have also developed specialized anti-sway cards based on their own brands. The application of these products has greatly improved the automation level of overhead crane operations.

4. Development of Automated Control and Management Software

The automated control system of an intelligent crane is crucial for realizing intelligent operations. This system can not only automatically start and stop the crane but also select the appropriate control mode based on different production tasks and execute handling tasks in order of priority.

To meet the demands of different working conditions, the management software of intelligent cranes needs to include various functional modules, such as interface subsystems, storage location inventory management subsystems, cargo identification subsystems, scheduling and crane operation subsystems, and spatial positioning subsystems. Through the coordinated operation of these functional modules, intelligent cranes can achieve fully automated operations, significantly improving work efficiency.

In addition, the information management software can collect and manage cargo inventory and production data in real-time, providing robust data support for automated inventory management and automated operations. By establishing connectivity between equipment and control systems through a factory-wide local area network, all collected information can be read and centrally managed in real-time.

5. 3D Spatial Positioning Technology

3D spatial positioning technology is a core technology for achieving high-precision operations with intelligent cranes. This technology achieves precise spatial positioning by monitoring the shape of the lifted items, detecting vacant positions, and performing one-dimensional, two-dimensional, and three-dimensional addressing of the actual storage location. It is particularly important for situations requiring high-precision operations, such as material handling and loading in automated production.

Currently, commonly used positioning sensors include limit switches, proximity switches, encoders, barcode locators, and rack and pinion positioning systems. Different sensors have their advantages and disadvantages in terms of positioning accuracy and application environments. The 3D spatial positioning technology of intelligent cranes typically requires the integration of multiple sensors to achieve higher positioning accuracy and operational stability.

6. Development of Intelligent Lifting Attachments

The development of intelligent crane lifting attachments is an essential aspect of intelligent crane applications. To meet the handling needs of different items, intelligent cranes require various types of lifting attachments (such as hooks, C hooks, lifting electromagnets, grab buckets, etc.). As the degree of intelligence increases, the design of lifting attachments also needs to evolve towards automation and intelligence.

Intelligent lifting attachments should not only have basic load-grabbing functions but also be capable of monitoring their operating status in real-time and transmitting this information to the control system through wireless transmission or bus communication. For lifting attachments with remote connectivity features, data can also be transmitted to the service center via the internet for remote maintenance and support.

Conclusion

The key technologies of intelligent cranes encompass various aspects, including safety monitoring, cargo identification, anti-sway technology, automated control, and spatial positioning. The development and application of these technologies not only enhance the automation level of cranes but also provide strong support for the development of intelligent manufacturing. As research deepens and technology continues to advance, intelligent cranes are expected to play an increasingly important role in industrial production in the future.