Material-based laser scanning system and method thereof

Abstract

The invention discloses a material-based laser scanning system and method, and relates to the technical field of industrial automation, and the system comprises the following components: a laser scanning unit, an environment sensing sensor group, a dynamic compensation and calibration module, a feedback control unit and a visual monitoring interface. According to the invention, the environment change of a scanning site is monitored in real time through the integrated environment sensing sensor group, and the laser scanning data is processed in real time by using an advanced dynamic compensation and calibration algorithm, so that the measurement deviation caused by environmental factors such as vibration, temperature change and dust interference can be effectively reduced; the measurement precision of laser scanning in complex environments such as a coal yard is remarkably improved, meanwhile, the stability of long-term measurement is ensured by continuously optimizing and calibrating model parameters and automatically adjusting laser scanning parameters, and reliable data support is provided for material management.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial automation, and in particular relates to a material-based laser scanning system and method thereof. Background Art

[0002] With the rapid development of industrial automation and intelligent warehousing technology, laser scanning systems, as an important tool for material management and inventory monitoring, have been widely used in bulk material yards such as coal yards, ports, and ore yards. By accurately measuring the contours, volumes, and distribution of material piles, they provide key data support for the company's production scheduling, inventory management, and logistics optimization. However, the working environment of bulk material yards is complex and changeable, involving a large amount of dust, temperature changes, mechanical vibrations and other unfavorable factors, which pose severe challenges to the measurement accuracy and stability of laser scanning systems.

[0003] Although traditional laser scanning systems have taken certain calibration measures when facing complex environments such as coal yards, they still have obvious deficiencies in dynamic compensation and real-time calibration. On the one hand, traditional calibration methods are mostly based on static or preset environmental conditions, and it is difficult to respond to the impact of environmental changes on measurement results in real time. On the other hand, traditional compensation algorithms often lack flexibility and intelligence, and cannot effectively deal with the complex coupling of multiple factors such as vibration, temperature fluctuations, and changes in dust concentration. Therefore, in the complex and changeable actual working environment, the measurement accuracy and stability of traditional laser scanning systems are difficult to guarantee, and it is difficult to meet the strict requirements of modern material management for high precision and high efficiency.

[0004] In view of the above problems, it is necessary to optimize the existing material-based laser scanning system and method thereof, and realize real-time perception, dynamic compensation and precise calibration of complex environmental changes by integrating a variety of high-precision environmental perception sensors, real-time data processing algorithms and intelligent feedback control mechanisms. Therefore, it is of great significance to develop a material-based laser scanning system and method thereof that can comprehensively realize the above characteristics. Summary of the invention

[0005] The purpose of the present invention is to make up for the shortcomings of the prior art and provide a material-based laser scanning system and method thereof. It can monitor environmental parameters such as vibration, temperature, and dust concentration in real time. The system can dynamically adjust laser scanning parameters and calibration models to effectively compensate for the influence of environmental factors on measurement results. It also has a high degree of automation and intelligence, and can independently complete a series of operations such as data preprocessing, adaptive compensation, calibration model optimization, and feedback control, without or with only a small amount of manual intervention. It not only significantly improves the measurement accuracy and stability of laser scanning in complex environments such as coal yards, but also greatly improves the efficiency and intelligence level of material management.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions: On the one hand, a material-based laser scanning system, characterized in that the system includes the following components: a laser scanning unit, an environment perception sensor group, a dynamic compensation and calibration module, a feedback control unit and a visual monitoring interface;

[0007] The laser scanning unit is used to emit a laser beam and receive a reflected signal to obtain distance and angle information of the coal pile surface;

[0008] The environmental perception sensor group includes a vibration sensor, a temperature sensor and a dust concentration sensor to monitor the environmental changes at the scanning site in real time;

[0009] The dynamic compensation and calibration module has a built-in dynamic compensation and calibration algorithm, and processes the laser scanning data in real time according to the data of the environment perception sensor group;

[0010] The feedback control unit automatically adjusts the laser scanning parameters and the calibration model according to the results of the dynamic compensation and calibration module;

[0011] The visual monitoring interface combines with a screen monitor to display the three-dimensional model, volume data and real-time change trend of the coal pile, and provides a management interface.

[0012] Furthermore, the laser scanning unit is configured according to parameters preset or adjusted by the feedback control unit. According to the set parameters, the laser scanning unit starts to emit a laser beam and receives a signal reflected from the surface of the coal pile, converts the received reflected signal into distance and angle data, and stores it inside the system or transmits it to the dynamic compensation and calibration module.

[0013] Furthermore, the environmental perception sensor group is started synchronously with the system, and each sensor begins to monitor environmental changes in real time. The vibration sensor detects the frequency and amplitude of mechanical vibration, the temperature sensor measures the ambient temperature, and the dust concentration sensor evaluates the dust content in the air. The collected environmental parameter data is stored in the system database in real time for subsequent processing. If abnormal environmental parameters are detected, an alarm mechanism is triggered to notify the operator.

[0014] Furthermore, the dynamic compensation and calibration module receives raw data from the laser scanning unit and the environmental perception sensor group, denoises and filters the laser scanning data to eliminate random errors and noise, and verifies the environmental parameter data and eliminates outliers. At the same time, based on the environmental parameter database and algorithm, it calculates the impact of the environmental parameters on the scanning results, and dynamically compensates the laser scanning data. Based on the compensated data and historical calibration data, the calibration model parameters are adjusted using an algorithm, and the processed scanning data is transmitted to a visual monitoring interface or stored in a database.

[0015] Furthermore, the dynamic compensation and calibration module calculates the influence of environmental parameters on the scanning results based on the environmental parameter database and algorithm, and the calculation formula is: ΔS=αV+β(T-T0)+γlog(1+D)+δ·V·T·D+∈, wherein α, β, γ, δ are environmental parameter coefficients, representing the direct and interactive influences of different environmental parameters on the scanning error, T0 is the reference temperature point used to center the temperature influence, log(1+D) is a nonlinear transformation of dust concentration, V·T·D represents the interaction between vibration, temperature and dust concentration, and ∈ is the residual term, representing the influence of other unknown factors on the scanning error in addition to these environmental parameters.

[0016] Furthermore, the dynamic compensation and calibration module uses an algorithm to adjust the calibration model parameters based on the compensated data and historical calibration data, and the algorithm formula is: Among them, θ t and θ t+1 are the calibration model parameters at the tth and t+1th iterations, respectively, η is the learning rate, which controls the step size of parameter update, represents the gradient of the parameter θ, L(D comp ,θ t ) is a loss function based on the compensated data, which measures the fitting degree of the calibration model to the compensated data under the current parameters. ( D hist ,θ t) is a regularization term, based on historical calibration data, used to prevent the model from overfitting and introduce constraints of historical knowledge, and λ is the weight of the regularization term.

[0017] Furthermore, the feedback control unit analyzes the results output by the dynamic compensation and calibration module, evaluates the effectiveness of the current scanning parameters and the calibration model, and automatically adjusts the laser scanning parameters and the calibration model parameters based on the evaluation results to optimize the scanning results, and sends the adjusted parameters to the laser scanning unit for real-time feedback control to continuously monitor the adjusted scanning results.

[0018] Furthermore, the feedback control unit automatically adjusts the laser scanning parameters and the calibration model parameters according to the evaluation results in the following specific steps:

[0019] (1) receiving the output from the data processing module, including the error between the measured data after dynamic compensation and the actual expected value, and calculating the error amount by comparing the measured value and the target value;

[0020] (2) based on the calculated error amount, the feedback control unit generates a feedback signal for indicating how to adjust the scanning parameters to reduce the error;

[0021] (3) Formulate a scanning parameter adjustment strategy based on the feedback signal;

[0022] (4) According to the formulated adjustment strategy, adjustment instructions are sent to the laser scanning unit through the control algorithm to modify the scanning parameters.

[0023] Furthermore, the feedback control unit sends an adjustment instruction to the laser scanning unit through a control algorithm to modify the scanning parameters, and the algorithm formula is: Among them, u ( t ) is the control signal, i.e. the adjustment instruction sent to the laser scanning unit, K p is the proportional gain, which determines the effect of the error on the current control action, e(t) is the error signal, that is, the difference between the measured value and the target value, K i is the integral gain, used to eliminate static errors, is the integral of the error, the cumulative error from time 0 to the current time t, K d is the derivative gain, which is used to predict future errors and adjust them in advance. is the differential of the error, that is, the rate of change of the error over time.

[0024] On the other hand, a laser scanning method based on a material, the specific steps of the method include:

[0025] S100, real-time monitoring: real-time monitoring of vibration and temperature parameters during scanning through environmental monitoring sensors;

[0026] S200, data analysis: the data processing and control unit performs a comprehensive analysis on the received environmental parameters and laser scanning data to determine whether dynamic compensation and calibration are required;

[0027] S300, model matching and adjustment: according to the current environmental parameters, the most suitable calibration model is selected from the calibration model library, and the model parameters are fine-tuned according to the actual situation;

[0028] S400, parameter adjustment: based on the calibration model, automatically adjust the scanning parameters of the laser scanning unit, including the scanning speed and the scanning angle, to eliminate the influence of environmental interference on the scanning result;

[0029] S500, feedback control: real-time monitoring of the adjusted scanning results through the feedback control mechanism. Compared with the prior art, the present invention has the following beneficial effects:

[0030] (1) The present invention monitors the environmental changes at the scanning site in real time by integrating an environmental perception sensor group, and processes the laser scanning data in real time using advanced dynamic compensation and calibration algorithms. This can effectively reduce the measurement deviation caused by environmental factors such as vibration, temperature change, and dust interference, and significantly improve the measurement accuracy of laser scanning in complex environments such as coal yards. At the same time, by continuously optimizing the calibration model parameters and automatically adjusting the laser scanning parameters, the stability of long-term measurements is ensured, providing reliable data support for material management.

[0031] (2) The present invention can automatically adjust and optimize scanning parameters through real-time data processing and feedback control mechanism, reducing dependence on manual intervention. In addition, the system is equipped with a visual monitoring interface that can intuitively display the three-dimensional model, volume data and real-time change trend of the coal pile, providing management personnel with a convenient and efficient monitoring method.

[0032] Other advantages, objectives and features of the present invention will be set forth in part in the following description and, in part, will be apparent to those skilled in the art based on an examination of the following or may be taught from the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0034] Figure 1 It is a process operation diagram of a material-based laser scanning system;

[0035] Figure 2 A flow chart of a material-based laser scanning method. DETAILED DESCRIPTION

[0036] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] Embodiment 1 :

[0038] This embodiment describes in detail a specific application of a material-based laser scanning system in a coal yard. The system integrates a laser scanning unit, an environmental perception sensor group (including a vibration sensor, a temperature sensor, and a dust concentration sensor), a dynamic compensation and calibration module, a feedback control unit, and a visual monitoring interface. It aims to achieve high-precision, real-time measurement of the surface morphology of the coal pile and adapt to the complex and changeable environmental conditions of the coal yard.

[0039] The laser scanning system is deployed at key locations in the coal yard to ensure that the laser scanning unit can cover the entire coal pile area. At the same time, the environmental perception sensor group also needs to be arranged in a suitable position to accurately monitor the environmental changes in the coal yard. Then the laser scanning system is started, and the laser scanning unit and the environmental perception sensor group start working synchronously. The laser scanning unit emits a laser beam according to preset or initialized parameters (such as laser intensity, scanning frequency, scanning angle range) and receives the reflected signal from the surface of the coal pile. The environmental perception sensor group monitors the vibration, temperature, dust concentration and other environmental parameters of the coal yard in real time.

[0040] The dynamic compensation and calibration module receives raw data from the laser scanning unit and the environmental perception sensor group. The laser scanning data includes information such as the intensity and time difference of the reflected signal, which can be used to calculate the distance and angle of the coal pile surface. The environmental perception data includes vibration frequency, amplitude, temperature value and dust concentration. The laser scanning data is first denoised and filtered to eliminate random errors and noise interference. Then, based on the historical data in the environmental parameter database and the real-time collected environmental parameters, a preset algorithm is used to calculate the impact of environmental parameters on the scanning results. Based on the impact of environmental parameters on the scanning results, the laser scanning data is dynamically compensated. The compensation process aims to eliminate measurement errors caused by environmental changes and improve the accuracy and reliability of scanning data. Based on the compensated data and historical calibration data, the calibration model parameters are adjusted using an optimization algorithm. The calibration model is used to describe the mapping relationship between laser scanning data and the actual coal pile morphology. By continuously optimizing the model parameters, the accuracy and stability of the mapping relationship can be improved.

[0041] The feedback control unit receives the output results of the dynamic compensation and calibration module, evaluates the effectiveness of the current scanning parameters and calibration model, calculates the error amount and generates a feedback signal by comparing the error between the measured value and the actual expected value, and formulates an adjustment strategy for the scanning parameters based on the feedback signal and the preset control strategy. Then, the control algorithm sends adjustment instructions to the laser scanning unit to modify the scanning parameters (such as laser intensity, scanning frequency, scanning angle range). The system continuously monitors the adjusted scanning results and continues to adjust the parameters as needed. Through continuous feedback and optimization process, the system can automatically adapt to changes in the coal yard environment and achieve high-precision and stable scanning.

[0042] The visual monitoring interface is combined with the screen monitor to display the three-dimensional model of the coal pile in real time. Through the three-dimensional model, managers can intuitively understand the shape and change trend of the coal pile. The interface also displays the volume data, real-time change trends and other related information of the coal pile. These data provide managers with a comprehensive basis for material management and provide a friendly management interface, allowing managers to view historical data, set scanning parameters, monitor system status, etc. Managers can perform material scheduling, inventory management and other related operations through the interface.

[0043] In summary, this embodiment achieves high-precision, real-time measurement and intelligent management of the surface morphology of coal piles by integrating advanced environmental perception, dynamic compensation and calibration, feedback control, and visual monitoring technologies. The system can adapt to the complex and changing environmental conditions of the coal yard, improve the efficiency and accuracy of material management, and provide strong support for the automation and intelligent transformation of the coal yard.

[0044] Embodiment 2 :

[0045] Based on Example 1, this example describes in detail the application of a dynamic calibration and optimization mechanism in a material-based laser scanning system, which achieves efficient and accurate monitoring of material morphology by real-time monitoring of environmental parameters, dynamic adjustment of calibration models, intelligent optimization of scanning parameters, and providing an intuitive visual management interface.

[0046] The environmental perception sensor group monitors parameters such as vibration, temperature and dust concentration in complex environments in real time, and transmits the data to the dynamic compensation and calibration module. The laser scanning unit continuously emits laser beams and receives reflected signals, and also transmits the original data to the dynamic compensation and calibration module.

[0047] The dynamic compensation and calibration module uses denoising and filtering algorithms to process laser scanning data, eliminate random errors and noise, and uses algorithms to calculate the impact of environmental parameters on scanning results based on real-time environmental parameters and historical calibration data. The calculation formula is: ΔS = αV + β(T-T0) + γlog(1+D) + δ·V·T·D+∈, where α, β, γ, δ are environmental parameter coefficients, representing the direct and interactive effects of different environmental parameters on scanning errors. T0 is the reference temperature point used to center the temperature effect. log(1+D) is a nonlinear transformation of dust concentration. V·T·D represents the interaction between vibration, temperature and dust concentration. ∈ is the residual term, representing the impact of other unknown factors on scanning errors in addition to these environmental parameters. The laser scanning data is dynamically compensated to eliminate measurement errors caused by environmental changes.

[0048] Based on the compensated data and historical calibration data, the optimization algorithm is used to adjust the calibration model parameters to improve the accuracy and generalization ability of the calibration model. The algorithm formula is: Among them, θ t and θ t+1 are the calibration model parameters at the tth and t+1th iterations, respectively, η is the learning rate, which controls the step size of parameter update, represents the gradient of the parameter θ, L(D comp ,θ t ) is a loss function based on the compensated data, which measures the fitting degree of the calibration model to the compensated data under the current parameters. hist ,θ t ) is a regularization term, which is based on historical calibration data and is used to prevent model overfitting and introduce historical knowledge constraints. λ is the weight of the regularization term. The adjusted calibration model parameters are applied to subsequent scanning data processing to improve the accuracy and stability of the scanning results.

[0049] The feedback control unit receives the output results of the dynamic compensation and calibration module, evaluates the effectiveness of the current scanning parameters and calibration model, and automatically generates adjustment instructions through the PID control algorithm or other advanced control strategies to adjust the scanning parameters (such as laser intensity, scanning frequency, scanning angle range) and calibration model parameters of the laser scanning unit, and monitors the system response in real time. The algorithm formula is: Among them, u(t) is the control signal, that is, the adjustment instruction sent to the laser scanning unit, K p is the proportional gain, which determines the effect of the error on the current control action, e ( t is the error signal, that is, the difference between the measured value and the target value, K i is the integral gain, used to eliminate static errors, is the integral of the error, the cumulative error from time 0 to the current time t, K d is the derivative gain, which is used to predict future errors and adjust in advance to improve the dynamic response of the system. It is the differential of the error, that is, the rate of change of the error over time. The parameters are continuously optimized according to the adjusted scanning results to achieve closed-loop control and continuous optimization of the system.

[0050] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A material-based laser scanning system, characterized in that: The system includes the following components: a laser scanning unit, an environment perception sensor group, a dynamic compensation and calibration module, a feedback control unit and a visual monitoring interface; The laser scanning unit is used to emit a laser beam and receive a reflected signal to obtain distance and angle information of the coal pile surface; The environmental perception sensor group includes a vibration sensor, a temperature sensor and a dust concentration sensor, which are used to monitor the environmental changes at the scanning site in real time; The dynamic compensation and calibration module has a built-in dynamic compensation and calibration algorithm, and processes the laser scanning data in real time according to the data of the environment perception sensor group; The feedback control unit automatically adjusts the laser scanning parameters and the calibration model according to the results of the dynamic compensation and calibration module; The visual monitoring interface combines with a screen monitor to display the three-dimensional model, volume data and real-time change trend of the coal pile, and provides a management interface.

2. A material-based laser scanning system according to claim 1, characterized in that: The laser scanning unit is configured according to parameters preset or adjusted by the feedback control unit. According to the set parameters, the laser scanning unit starts to emit a laser beam and receives a signal reflected from the surface of the coal pile, converts the received reflected signal into distance and angle data, and stores it inside the system or transmits it to the dynamic compensation and calibration module.

3. The material-based laser scanning system according to claim 1, characterized in that: The environmental perception sensor group is started synchronously with the system, and each sensor begins to monitor environmental changes in real time. The vibration sensor detects the frequency and amplitude of mechanical vibration, the temperature sensor measures the ambient temperature, and the dust concentration sensor evaluates the dust content in the air. The collected environmental parameter data is stored in the system database in real time for subsequent processing. If abnormal environmental parameters are detected, an alarm mechanism is triggered to notify the operator.

4. The material-based laser scanning system according to claim 1, characterized in that: The dynamic compensation and calibration module receives raw data from the laser scanning unit and the environmental perception sensor group, denoises and filters the laser scanning data to eliminate random errors and noise, verifies the environmental parameter data and removes outliers, and calculates the impact of environmental parameters on the scanning results based on the environmental parameter database and algorithm, and dynamically compensates the laser scanning data. Based on the compensated data and historical calibration data, the calibration model parameters are adjusted using an algorithm, and the processed scanning data is transmitted to a visual monitoring interface or stored in a database.

5. A material-based laser scanning system according to claim 4, characterized in that: The dynamic compensation and calibration module calculates the influence of environmental parameters on the scanning results according to the environmental parameter database and algorithm, and the calculation formula is: ΔS=αV+β(T-T0)+γlog(1+D)+δ·V·T·D+∈, wherein α, β, γ, δ are environmental parameter coefficients, representing the direct and interactive influences of different environmental parameters on the scanning error, T0 is the reference temperature point used to center the temperature influence, log(1+D) is the nonlinear transformation of dust concentration, V·T·D represents the interaction between vibration, temperature and dust concentration, ∈ is the residual term, representing the influence of other unknown factors on the scanning error except these environmental parameters.

6. The material-based laser scanning system according to claim 4, characterized in that: The dynamic compensation and calibration module uses an algorithm to adjust the calibration model parameters based on the compensated data and historical calibration data. The algorithm formula is: Among them, θ t and θ t+1 are the calibration model parameters at the tth and t+1th iterations, respectively, η is the learning rate, which controls the step size of parameter update, represents the gradient of the parameter θ, L(D comp ,θ t It is a loss function based on the compensated data, which measures the fitting degree of the calibration model to the compensated data under the current parameters. hist ,θ t ) is a regularization term, which is based on historical calibration data and is used to prevent the model from overfitting and introduce constraints of historical knowledge. λ is the weight of the regularization term.

7. The material-based laser scanning system according to claim 1, characterized in that: The feedback control unit analyzes the results output by the dynamic compensation and calibration module, evaluates the effectiveness of the current scanning parameters and the calibration model, and automatically adjusts the laser scanning parameters and the calibration model parameters according to the evaluation results to optimize the scanning results. The adjusted parameters are sent to the laser scanning unit for real-time feedback control and continuous monitoring of the adjusted scanning results.

8. The material-based laser scanning system according to claim 7, characterized in that: The specific steps of the feedback control unit automatically adjusting the laser scanning parameters and the calibration model parameters according to the evaluation results are as follows: (1) receiving the output from the data processing module, including the error between the measured data after dynamic compensation and the actual expected value, and calculating the error amount by comparing the measured value and the target value; (2) based on the calculated error amount, the feedback control unit generates a feedback signal for indicating how to adjust the scanning parameters to reduce the error; (3) Formulate a scanning parameter adjustment strategy based on the feedback signal; (4) According to the formulated adjustment strategy, adjustment instructions are sent to the laser scanning unit through the control algorithm to modify the scanning parameters.

9. The material-based laser scanning system according to claim 8, characterized in that: The feedback control unit sends an adjustment instruction to the laser scanning unit through a control algorithm to modify the scanning parameters. The algorithm formula is: Among them, u(t is the control signal, that is, the adjustment instruction sent to the laser scanning unit, K p is the proportional gain, which determines the effect of the error on the current control action, e ( t ) is the error signal, i.e. the difference between the measured value and the target value, K i is the integral gain, used to eliminate static errors, is the integral of the error, the cumulative error from time 0 to the current time t, K d is the differential gain, which is used to predict future errors and make adjustments in advance. is the differential of the error, that is, the rate of change of the error over time.

10. A laser scanning method based on materials, characterized in that: The specific steps of the method include: S100, real-time monitoring: real-time monitoring of vibration and temperature parameters during scanning through environmental monitoring sensors; S200, data analysis: the data processing and control unit performs a comprehensive analysis on the received environmental parameters and laser scanning data to determine whether dynamic compensation and calibration are required; S300, model matching and adjustment: according to the current environmental parameters, the most suitable calibration model is selected from the calibration model library, and the model parameters are fine-tuned according to the actual situation; S400, parameter adjustment: based on the calibration model, automatically adjust the scanning parameters of the laser scanning unit, including the scanning speed and the scanning angle, to eliminate the influence of environmental interference on the scanning result; S500, feedback control: through the feedback control mechanism, the adjusted scanning results are monitored in real time.

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