Overhead crane is the main equipment for lifting and transporting in large factories and workshops, which is commonly used in metallurgy, papermaking, building materials and other large manufacturing workshops. Large workshops usually have multiple cranes working simultaneously on the same track, often due to untimely brakes leading to collisions, affecting production efficiency and causing danger at the same time.

The overhead crane anti-collision device measures the distance between the overhead cranes on the same track and the distance between the overhead crane and the track end in real time, sets the safety warning distance, controls the overhead crane, and informs the driver to pay attention to the distance between the overhead cranes in time to ensure production safety.

Benewake single-point LiDAR module product models are abundant. It is not affected by ambient light and other interference sources. The maximum range models detection distance up to 350m, measurement accuracy cm level, detection frequency up to 1000Hz, pure industrial scene design, with IP65/67 protection level, which can provide stability and reliability for the overhead crane collision avoidance device.

Program Introduction 

1. Diagram

2.Logic Diagram

3.Scheme description

According to operating directions of the overhead cranes, the running front is judged to be the overhead crane or the rail terminal, and different alarm intervals are set. In the red area in the figure, the close range within L2 from the overhead crane is set to prevent collision, and set the emergency brake area ①; the area a little farther away is set as deceleration area ②. In the yellow area, the distance between the overhead cranes D is between L1 and L2; the area with a distance larger than L1 is the normal driving area ③.

In the operating direction of the overhead crane, the deceleration threshold L1 is usually set 15m, LiDAR continuously detects the real-time distance D between two overhead cranes. When value D is less than L1 threshold, the overhead crane decelerates and runs. The emergency brake threshold is usually set 5m, when the real-time distance D between two overhead cranes is less than L2 emergency brake threshold, it works to prevent the overhead crane from collision.

If the front end of the overhead crane operating direction is the rail terminal, and no other overhead crane exists between them, the deceleration threshold L1 is usually set to 10m and the emergency brake threshold L2 is set to 3m.

Set up when the distance value is within the alarm interval, the control triggers the sound and optical module alarm to prompt the driver to pay attention to safety.

4.Installation

The TF-LiDAR is installed on both sides of the overhead crane operating direction to detect the left/right interval distance. Two LiDARs are installed at the diagonal of the overhead crane to prevent the correlation caused by the LiDARs of two overhead cranes. The LiDARs are installed to align the target object, and the light spot center is aligned with the target object with the use of indicating laser and infrared camera.

Solution Advantages

① The default detection frequency is 100Hz, and the maximum configuration is 1000Hz, which can be configured to meet high-speed operation scenarios and timely response.

② It can also output real-time distance and signal strength values. Simple data parsing, with the ability to do more credible processing with intensity values.

③ Rich interface. Supports UART/I²C/4-20mA/RS-232/RS-485 multiple data interfaces.

④ High interference resistance. Ambient light resistance of 100Klux.

⑤ Highly adaptable, no requirement for reflectors, no need to install strong reflectance reflector board.